ASTM D5966-22

Standard Test Method for Evaluation of Engine Oils for Roller Follower Wear in Light-Duty Diesel Engine

SIGNIFICANCE AND USE
5.1 This test method is used to determine the ability of an engine crankcase oil to control wear that can develop in the field under low to moderate engine speeds and heavy engine torques. Side-by-side comparisons of two or more oils in delivery van fleets were used to demonstrate the field performance of various oils. The specific operating conditions of this test method were developed to provide correlation with the field performance of these oils.  
5.2 This test method, along with other test methods, defines the minimum performance level of the Category API CG-4 for heavy duty diesel engine lubricants. Passing limits for this category are included in Specification D4485.  
5.3 The design of the engine used in this test method is not representative of all modern diesel engines. Consider this factor, along with the specific operating conditions used to accelerate wear, when extrapolating test results.
SCOPE
1.1 This engine lubricant test method is commonly referred to as the Roller Follower Wear Test. Its primary result, roller follower shaft wear in the hydraulic valve lifter assembly, has been correlated with vehicles used in stop-and-go delivery service prior to 1993. It is one of the test methods required to evaluate lubricants intended to satisfy the API CG-4 performance category. This test has also been referred to as the 6.2 L Test.  
1.2 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.2.1 Exceptions—Where there is no direct SI equivalent, such as pipe fittings, thermocouple diameters, and NPT screw threads. Also, roller follower wear is measured in mils.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 Table of Contents:    
Section  
Scope  
1  
Referenced Documents  
2  
Terminology  
3  
Summary of Test Method  
4  
Significance and Use  
5  
Reagents  
7  
Guidelines on Substitution  
7.1  
Apparatus  
6  
Preparation of Apparatus  
8  
New Engine Preparation  
8.1  
Installation of Auxiliary Systems and
Miscellaneous Components  
8.2  
Test Procedure  
9  
Description of Test Segments and Organization
of Test Procedure Sections  
9.1  
Engine Parts Replacement  
9.2  
Engine Starting Procedure  
9.3  
Normal Engine Shutdown Procedure  
9.4  
Emergency Shutdown Procedure  
9.5  
Unscheduled Shutdown and Downtime  
9.6  
New Engine Break-In  
9.7  
Pretest Procedure  
9.8  
Fifty-Hour Steady State Test  
9.9  
Periodic Measurements  
9.10  
Oil Sampling and Oil Addition Procedures  
9.11  
End of Test (EOT) Procedure  
9.12  
Calculation and Interpretation of Test Results  
10  
Environment of Parts Measurement Area  
10.1  
Roller Follower Shaft Wear Measurements  
10.2  
Oil Analysis  
10.3  
Assessment of Test Validity  
10.4  
Final Test Report  
11  
Reporting Calibration Test Results  
11.1  
Report Forms  
11.2  
Interim Non-Valid Calibration Test Summary  
11.3  
Severity Adjustments  
11.4  
Precision and Bias  
12  
Precision  
12.1  
Precision Estimate  
12.2  
Bias  
12.3  
Keywords  
13  
ANNEXES    
Guidelines for Test Part Substitution or Modification  
Annex A1  
Guidelines for Units and Specification Formats  
Annex A2  
Detailed Specifications of Apparatus  
Annex A3  
Calibration  
Annex A4  
Final Report Forms  
Annex A5  
Illustrations  
Annex A6  
Kinematic Viscosity at 100°C Procedure for the
Roller Follower Wear Test  
Annex A7  
Enhanced Thermal Gravimetric Analysis (TGA)
Procedure for Soot Measurement  
Annex A8  
Sources of Mat...

General Information

• Status: Published
• Publication Date: 31-Mar-2022
• ICS: 19.020 - Test conditions and procedures in general
• ICS: 75.100 - Lubricants, industrial oils and related products
• Technical Committee: D02 - Petroleum Products, Liquid Fuels, and Lubricants
• Drafting Committee: D02.B0.02 - Heavy Duty Engine Oils

Relations

• Refers: ASTM D445-24 - Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)
• Effective Date: 01-Apr-2024
• Refers: ASTM D613-24 - Standard Test Method for Cetane Number of Diesel Fuel Oil
• Effective Date: 01-Feb-2024
• Refers: ASTM D4175-23a - Standard Terminology Relating to Petroleum Products, Liquid Fuels, and Lubricants
• Effective Date: 15-Dec-2023
• Refers: ASTM D7422-23 - Standard Test Method for Evaluation of Diesel Engine Oils in T-12 Exhaust Gas Recirculation Diesel Engine
• Effective Date: 01-Dec-2023
• Refers: ASTM D86-23ae1 - Standard Test Method for Distillation of Petroleum Products and Liquid Fuels at Atmospheric Pressure
• Effective Date: 01-Dec-2023
• Refers: ASTM D86-23a - Standard Test Method for Distillation of Petroleum Products and Liquid Fuels at Atmospheric Pressure
• Effective Date: 01-Dec-2023
• Refers: ASTM D445-23 - Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)
• Effective Date: 01-Nov-2023
• Refers: ASTM D4175-23e1 - Standard Terminology Relating to Petroleum Products, Liquid Fuels, and Lubricants
• Effective Date: 01-Jul-2023
• Refers: ASTM D93-20 - Standard Test Methods for Flash Point by Pensky-Martens Closed Cup Tester
• Effective Date: 01-Aug-2020
• Refers: ASTM D4485-18 - Standard Specification for Performance of Active API Service Category Engine Oils
• Effective Date: 01-Jul-2018
• Refers: ASTM D5185-18 - Standard Test Method for Multielement Determination of Used and Unused Lubricating Oils and Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)
• Effective Date: 01-Apr-2018
• Refers: ASTM D613-17c - Standard Test Method for Cetane Number of Diesel Fuel Oil
• Effective Date: 01-Dec-2017
• Refers: ASTM D7422-17a - Standard Test Method for Evaluation of Diesel Engine Oils in T-12 Exhaust Gas Recirculation Diesel Engine
• Effective Date: 01-Oct-2017
• Refers: ASTM D613-17a - Standard Test Method for Cetane Number of Diesel Fuel Oil
• Effective Date: 01-May-2017
• Refers: ASTM D7422-17 - Standard Test Method for Evaluation of Diesel Engine Oils in T-12 Exhaust Gas Recirculation Diesel Engine
• Effective Date: 01-May-2017

Overview

ASTM D5966-22, titled "Standard Test Method for Evaluation of Engine Oils for Roller Follower Wear in Light-Duty Diesel Engine," is a key ASTM International standard used to assess the wear protection performance of engine oils in light-duty diesel engines. This standard focuses on the evaluation of roller follower shaft wear within the hydraulic valve lifter assembly. The Roller Follower Wear Test, sometimes called the 6.2 L Test, simulates real-world conditions-specifically those found in stop-and-go delivery vehicles-and is essential for qualifying lubricants for the API CG-4 performance category.

Key Topics

• Roller Follower Wear Testing: The method measures wear on roller follower shafts as an indicator of lubricant protection in demanding service conditions.
• Simulated Real-World Operation: Test conditions replicate stop-and-go driving with low to moderate speeds and heavy engine torques to closely match field experiences.
• Reference Oils: Use of oils with known characteristics helps laboratories calibrate results and ensure test method consistency.
• Data Collection and Interpretation: Detailed procedures specify oil analysis, wear measurement, calibration, and the reporting of results.
• Safety and Environmental Practices: Laboratories are responsible for following all safety, health, and environmental guidelines during testing.
• Testing Apparatus and Calibration: Strict requirements address the preparation of test engines, subsystems, and instrumentation to control variables and enhance repeatability.
• Statistical Assessment: Precision and bias are addressed using industry-standard techniques, and severity adjustments are available to control for laboratory variability.

Applications

• Engine Oil Qualification: This standard is a required procedure for engine oils designed to meet the API CG-4 category, which is used in heavy-duty and light-duty diesel engines.
• Field Correlation: By aligning lab results with field data-specifically from delivery van fleets-manufacturers can confidently predict in-service performance.
• Research and Development: Oil formulators use ASTM D5966-22 to screen new additive technologies and optimize base oil blends for improved wear protection.
• Quality Assurance: Oil blenders and marketers rely on this standardized method for routine batch testing, ensuring consistent product performance.
• Regulatory Compliance: The method supports compliance with industry and military specifications that require proven roller follower wear protection.
• Benchmarking and Comparison: Enables side-by-side product comparisons, assisting end users and procurement specialists in lubricant selection.

Related Standards

• ASTM D4485: Specification for Performance of Active API Service Category Engine Oils; establishes passing criteria related to this test.
• ASTM D445: Test Method for Kinematic Viscosity, relevant for oil analysis during and after testing.
• ASTM D5185: Used for multi-element determination (wear metals) in oil analysis.
• ASTM D7422: Another method for evaluating diesel engine oil performance, particularly with exhaust gas recirculation systems.
• API CG-4: The American Petroleum Institute’s category for heavy-duty diesel engine oils; ASTM D5966-22 is part of the qualification suite for this category.
• ISO/TC 28: International context for petroleum product standards.
• SAE J300: Provides viscosity grade classifications referenced for break-in oil.

Practical Value

ASTM D5966-22 provides lubricant manufacturers, testing laboratories, and end users with a robust, repeatable method to quantify the ability of engine oils to protect against roller follower wear in light-duty diesel applications. Its close correlation with field performance ensures reliable product quality, extends engine life, and helps meet evolving regulatory and customer demands. By using standardized test data, stakeholders can effectively compare oil formulations, maintain industry compliance, and uphold confidence in lubrication solutions for light-duty diesel engines.

Keywords: engine oil, roller follower wear, ASTM D5966-22, light-duty diesel, lubricant testing, API CG-4, oil performance, wear protection, standardized test method, diesel engine oil evaluation

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D5966 − 22
Standard Test Method for
Evaluation of Engine Oils for Roller Follower Wear in Light-
Duty Diesel Engine
This standard is issued under the fixed designation D5966; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
INTRODUCTION
This test method is continually undergoing changes to reflect refinements in procedure, obsoles-
cenceofpartsorreagents.Thesechangesorupdates,aswellasgeneralinformationregardingthetest
method, are issued as information letters by the ASTM Test Monitoring Center (TMC). Copies of
information letters pertaining to the test method may be obtained by contacting the ASTM Test
Monitoring Center.
Thetestmethodcanbeusedbyanyproperlyequippedlaboratory,withoutassistanceofanyonenot
associated with that laboratory. However, TMC provides reference oils and an assessment of the test
resultsobtainedonthoseoilsbythelaboratory.Bythismeans,thelaboratorywillknowwhethertheir
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 imposes such a requirement,
in connection with several military lubricant specifications.
Accordingly, this test method is written for use by laboratories which utilize the TMC services.
Laboratories that choose not to use these services may simply ignore those portions of the test
procedure which refer to the TMC.
1. Scope 1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
1.1 This engine lubricant test method is commonly referred
responsibility of the user of this standard to establish appro-
to as the Roller Follower Wear Test. Its primary result, roller
priate safety, health, and environmental practices and deter-
follower shaft wear in the hydraulic valve lifter assembly, has
mine the applicability of regulatory limitations prior to use.
been correlated with vehicles used in stop-and-go delivery
service prior to 1993. It is one of the test methods required to
1.4 Table of Contents:
evaluate lubricants intended to satisfy the API CG-4 perfor-
Section
mance category.This test has also been referred to as the 6.2 L Scope 1
Referenced Documents 2
Test.
Terminology 3
Summary of Test Method 4
1.2 The values stated in SI units are to be regarded as
Significance and Use 5
standard. No other units of measurement are included in this
Reagents 7
standard.
Guidelines on Substitution 7.1
Apparatus 6
1.2.1 Exceptions—Where there is no direct SI equivalent,
Preparation of Apparatus 8
such as pipe fittings, thermocouple diameters, and NPT screw
New Engine Preparation 8.1
threads. Also, roller follower wear is measured in mils.
Installation of Auxiliary Systems and 8.2
Miscellaneous Components
Test Procedure 9
Description of Test Segments and Organization 9.1
This test method is under the jurisdiction of ASTM Committee D02 on
of Test Procedure Sections
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of Engine Parts Replacement 9.2
Subcommittee D02.B0.02 on Heavy Duty Engine Oils. Engine Starting Procedure 9.3
Normal Engine Shutdown Procedure 9.4
Current edition approved April 1, 2022. Published April 2022. Originally
Emergency Shutdown Procedure 9.5
approved in 1996. Last previous edition approved in 2013 as D5966–13, which
Unscheduled Shutdown and Downtime 9.6
waswithdrawnJanuary2022andreinstatedinApril2022.DOI:10.1520/D5966-22.
New Engine Break-In 9.7
ASTM Test Monitoring Center, 203 Armstrong Drive, Freeport, PA 16229,
Pretest Procedure 9.8
www.astmtmc.org. This edition incorporated revisions contained in all Information
Fifty-Hour Steady State Test 9.9
Letters through No. 12-1.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D5966 − 22
D664Test Method for Acid Number of Petroleum Products
Periodic Measurements 9.10
Oil Sampling and Oil Addition Procedures 9.11
by Potentiometric Titration
End of Test (EOT) Procedure 9.12
D976Test Method for Calculated Cetane Index of Distillate
Calculation and Interpretation of Test Results 10
Fuels
Environment of Parts Measurement Area 10.1
Roller Follower Shaft Wear Measurements 10.2
D1319Test Method for HydrocarbonTypes in Liquid Petro-
Oil Analysis 10.3
leum Products by Fluorescent Indicator Adsorption
Assessment of Test Validity 10.4
D2274TestMethodforOxidationStabilityofDistillateFuel
Final Test Report 11
Reporting Calibration Test Results 11.1
Oil (Accelerated Method)
Report Forms 11.2
D2500Test Method for Cloud Point of Petroleum Products
Interim Non-Valid Calibration Test Summary 11.3
Severity Adjustments 11.4 and Liquid Fuels
Precision and Bias 12
D2622Test Method for Sulfur in Petroleum Products by
Precision 12.1
Wavelength Dispersive X-ray Fluorescence Spectrometry
Precision Estimate 12.2
Bias 12.3 D2709Test Method for Water and Sediment in Middle
Keywords 13
Distillate Fuels by Centrifuge
ANNEXES
D4052Test Method for Density, Relative Density, and API
Guidelines for Test Part Substitution or Modification Annex A1
Gravity of Liquids by Digital Density Meter
Guidelines for Units and Specification Formats Annex A2
Detailed Specifications of Apparatus Annex A3
D4175Terminology Relating to Petroleum Products, Liquid
Calibration Annex A4
Fuels, and Lubricants
Final Report Forms Annex A5
Illustrations Annex A6 D4485Specification for Performance ofActiveAPI Service
Kinematic Viscosity at 100°C Procedure for the Annex A7
Category Engine Oils
Roller Follower Wear Test
D4737Test Method for Calculated Cetane Index by Four
Enhanced Thermal Gravimetric Analysis (TGA) Annex A8
Procedure for Soot Measurement Variable Equation
Sources of Materials and Information Annex A9
D5185Test Method for Multielement Determination of
APPENDIXES
Used and Unused Lubricating Oils and Base Oils by
PC-9 Reference Diesel Fuel Properties Appendix X1
Diagnostic Data Review Appendix X2
Inductively Coupled Plasma Atomic Emission Spectrom-
etry (ICP-AES)
1.5 This international standard was developed in accor-
dance with internationally recognized principles on standard- D7422Test Method for Evaluation of Diesel Engine Oils in
T-12 Exhaust Gas Recirculation Diesel Engine
ization established in the Decision on Principles for the
Development of International Standards, Guides and Recom- E29Practice for Using Significant Digits in Test Data to
Determine Conformance with Specifications
mendations issued by the World Trade Organization Technical
Barriers to Trade (TBT) Committee.
2.2 American National Standards Institute (ANSI):
MC96.1Temperature Measurement Thermocouples
2. Referenced Documents
2.1 ASTM Standards:
3. Terminology
D86Test Method for Distillation of Petroleum Products and
3.1 Definitions:
Liquid Fuels at Atmospheric Pressure
3.1.1 blowby, n—in internal combustion engines, that por-
D93Test Methods for Flash Point by Pensky-Martens
tion of the combustion products and unburned air/fuel mixture
Closed Cup Tester
that leaks past piston rings into the engine crankcase during
D97Test Method for Pour Point of Petroleum Products
operation.
D130Test Method for Corrosiveness to Copper from Petro-
3.1.2 BTDC (before top dead center), n—used with the
leum Products by Copper Strip Test
degreesymboltoindicatetheangularpositionofthecrankshaft
D235Specification for Mineral Spirits (Petroleum Spirits)
relative to its position at the point of uppermost travel of the
(Hydrocarbon Dry Cleaning Solvent)
piston in the cylinder.
D287Test Method forAPI Gravity of Crude Petroleum and
Petroleum Products (Hydrometer Method)
3.1.3 calibrate, v—todeterminetheindicationoroutputofa
D445Test Method for Kinematic Viscosity of Transparent
device (e.g., thermometer, manometer, engine) with respect to
and Opaque Liquids (and Calculation of DynamicViscos-
that of a standard.
ity)
3.1.4 candidate oil, n—an oil which is intended to have the
D446Specifications and Operating Instructions for Glass
performance characteristics necessary to satisfy a specification
Capillary Kinematic Viscometers
and is tested against that specification. D4175
D482Test Method for Ash from Petroleum Products
3.1.5 engine oil, n—aliquidthatreducesfrictionorwear,or
D524Test Method for Ramsbottom Carbon Residue of
both, between the moving parts within an engine; removes
Petroleum Products
heat, particularly from the underside of pistons; and serves as
D613Test Method for Cetane Number of Diesel Fuel Oil
a combustion gas sealant for piston rings.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
the ASTM website. 4th Floor, New York, NY 10036.
D5966 − 22
3.1.5.1 Discussion—It may contain additives to enhance 5.3 The design of the engine used in this test method is not
certain properties. Inhibition of engine rusting, deposit representative of all modern diesel engines. Consider this
formation, valve train wear, oil oxidation and foaming are factor, along with the specific operating conditions used to
examples. D4175 accelerate wear, when extrapolating test results.
3.1.6 light-duty, adj—in internal combustion engine
6. Apparatus
operation, characterized by average speeds, power output, and
internal temperatures that are generally much lower than the
6.1 Alisting and complete description of all apparatus used
potential maximums. D4485
in the test is found in Annex A3. Information concerning
3.1.7 light-duty engine, n—in internal combustion engine procurement of apparatus can be found in Appendix X1.
types, one that is designed to be normally operated at substan-
tially less than its peak output. D4485
7. Reagents
3.1.8 lubricant, n—any material interposed between two
7.1 Guidelines on Substitution—No substitutions for the
surfaces that reduces friction or wear, or both, between them.
reagents listed in 7.1.1 – 7.1.3 are allowed.
D4175
7.1.1 Cleaning Solvent,Forcleaningparts,useonlymineral
3.1.9 lubricating oil, n—a liquid lubricant, usually compris-
spirits meeting the requirements of Specification D235, Type
ing several ingredients, including a major portion of base oil
II, Class C forAromatic Content (volume fraction (0 to 2) %),
and minor portions of various additives. D4175
FlashPoint(61°C,min)andColor(notdarkerthan+25onthe
3.1.10 reference oil, n—an oil of known performance Saybolt Scale or 25 on Pt-Co Scale. (Warning—Combustible.
characteristics, used as a basis for comparison. Health hazard.) Obtain a Certificate ofAnalysis for each batch
3.1.10.1 Discussion—Reference oils are used to calibrate of solvent from the supplier.
testing facilities, to compare the performance of other oils, or
7.1.2 Engine Coolant—The engine coolant is a solution of
to evaluate other materials (such as seals) that interact with
demineralized water that has less than 0.03 g/kg dissolved
oils. D4175
solids and an ethylene glycol based anti-freeze mixed at the
following concentration—70% antifreeze and 30% water by
3.1.11 used oil, n—any oil that has been in a piece of
volume.
equipment (for example, an engine, gearbox, transformer, or
turbine), whether operated or not. D4175
7.1.2.1 Demineralized Water, is used as a generic term to
describe pure water. Deionized or distilled water may also be
3.1.12 wear, n—the loss of material from a surface, gener-
used as long as the total dissolved solids content is less than
ally occurring between two surfaces in relative motion, and
0.03 g/kg.
resultingfrommechanicalorchemicalaction,oracombination
of both. D7422 7.1.3 Fuel—Approximately 600 L of either PC-9 or PC-
9-HS Reference Diesel Fuel are required for each test.
4. Summary of Test Method
(Warning—Combustible. Health hazard. Use adequate safety
4.1 A pre-assembled GM V8 diesel test engine is installed provisions.)
on a test stand and operated for 50 h.
7.1.3.1 Fuel Batch Analysis—Each fuel shipment does not
need to be analyzed upon receipt from the supplier. However,
4.2 The test engine operating conditions are generally more
laboratories are responsible for periodic checks for contamina-
extreme than typical service operating conditions. These con-
tion. Any analysis results for parameters tested should be
ditions provide high soot loading and accelerated roller fol-
within the tolerances shown on Form 20. If any results fall
lower shaft wear while maintaining correlation with wear
outsidethetolerancesshownonForm20,thelaboratoryshould
levels found in the field.
contact the Test Monitoring Center (TMC) for help in resolv-
4.3 At the end of the test, the performance of the engine oil
ing the problem.
is determined by measuring the level of wear on the roller
7.1.3.2 Fuel Batch Storage—The fuel should be stored in
follower shafts.
accordance with all applicable safety and environmental regu-
lations.
5. Significance and Use
7.1.4 Break-In Oil—Approximately 8 kg of break-in oil are
5.1 This test method is used to determine the ability of an
necessary for new engine break-in. Break-in oil is defined as
engine crankcase oil to control wear that can develop in the
any SAE 15W-40, API CG-4 quality oil.
field under low to moderate engine speeds and heavy engine
torques. Side-by-side comparisons of two or more oils in 7.1.5 Non-Reference Test Oil—Aminimum of 20 kg of new
delivery van fleets were used to demonstrate the field perfor- oilarerequiredtocompletethetest.A25kgsampleofnewoil
manceofvariousoils.Thespecificoperatingconditionsofthis is normally provided to allow for inadvertent losses.
test method were developed to provide correlation with the
7.1.6 Calibration Test Oil—A22 kg sample of reference oil
field performance of these oils.
is provided by the TMC for each calibration test.
5.2 This test method, along with other test methods, defines
the minimum performance level of the CategoryAPI CG-4 for
heavy duty diesel engine lubricants. Passing limits for this
Available from Chevron Phillips, Phillips 66 Co., Marketing Services Center,
category are included in Specification D4485. P.O. Box 968, Borger, TX 79008–0968.
D5966 − 22
8. Preparation of Apparatus 9. Test Procedure
8.1 New Engine Preparation—Paragraphs 8.1.1 through 9.1 Description of Test Segments and Organization of Test
Procedure Sections:
8.1.7 describe preparations that are only performed on a new
engine before conducting the new engine break-in. 9.1.1 New Engine Break-in—A break-in is only performed
on a new engine. A break-in is not performed before each
8.1.1 Engine Front Cover Installation—Install the front
steady state test. New engine break-in is detailed in 9.7.
cover to the front of the engine block with the gasket supplied
9.1.2 Pretest Procedure—The pretest segment is used to
and torque all bolts to 40 N·m.
flush previous oil from the test engine and is performed before
8.1.2 Oil Sump Drain Location—Install a drain in the sump
each 50 h wear test. Pretest segment is detailed in 9.8.
as described in A3.9.3.7.
9.1.3 Fifty-Hour Steady State Test—The actual test used to
8.1.3 Glow Plug Replacement—Removetheglowplugsand
measure roller follower shaft wear is a 50 h test run at steady
install 27in. dry seal NPT socket pressure plugs. Torque the
state conditions shown in Table 1. Paragraph 9.9 describes the
plugs to 20 N·m.
operation of the 50 h test.
8.1.4 Cold Start Solenoid Disablement—Disconnect the
9.1.4 Engine Starting and Shutdown Procedures—
cold start solenoid.
Paragraphs9.3–9.5describetheenginestartingandshutdown
8.1.5 Exhaust Manifolds—Check the flanges to ensure the
procedures.
gasket surfaces are not distorted. Install the required water-
cooledexhaustmanifoldswiththedischargetowardtherearof
9.2 Engine Parts Replacement—Therollerfollowerscannot
the engine. Use the special studs supplied with the manifolds, be replaced during the test. Record the circumstances involved
and torque the studs to 30 N·m.
in any other engine parts replacement on the Supplemental
8.1.6 Rocker Arm Cover Preparation—Install a new seal to Operational Data pages.
each rocker arm cover lid. Install a new gasket on each rocker
9.3 Engine Starting Procedure—Use the following proce-
arm cover mounting flange. Install the rocker arm covers, but
dure each time the engine is started:
not the lids, at this time.
9.3.1 Turn on the safety circuits and the engine coolant
pump.
NOTE 1—The rocker arm cover lid is removed after each test. An
adhesive material may be used to adhere the gasket to the rocker arm
9.3.2 Crank the engine.
cover lid. Installation of a small amount of petroleum jelly to the sealing
9.3.3 The control systems shall allow the engine to start
surface facilitates removal and extends the life of the seal.
within 10 s. (Warning—Verify that the oil sump and cooling
8.1.7 Injection Pump Position Verification—Verify the dy-
system have been charged before starting the engine.)
namic timing marks on the engine and injection pump flanges
(Warning—Verify there is an adequate supply of cooling
are properly aligned. The mark is a line scribed across the top
water to the exhaust manifolds and external heat exchangers.
ofthepumpmountingflangeandtheinjectionpumpgeardrive
Without sufficient coolant flow, the engine and exhaust mani-
cover flange.
folds will overheat and sustain serious damage.)
(Warning—Donotspraystartingfluidsintotheintake-airhorn
8.2 Installation of Auxiliary Systems and Miscellaneous
to assist engine starting.) (Warning—Do not crank the engine
Components:
excessively. If starting difficulties are encountered, perform
8.2.1 Exhaust Back Pressure Transducer Lines—Check the
diagnostics to determine why engine will not start. Excessive
lines leading to the pressure transducer. Remove any obstruc-
cranking times may promote increased engine wear.)
tions in the lines.
8.2.2 Crankcase Ventilation System—Clean the oil separa-
tor.Installthecrankcaseventtubetotheatmospherebywayof
the oil separator on the rear of the right rocker arm cover as
TABLE 1 Steady State Operating Conditions
shown in Fig. A3.3.
Parameter Specification
8.2.3 External Oil System Installation—Configuretheexter-
Speed, r/min 1000 ± 5
nal oil system according to the schematic diagram shown in
Torque, N·m Record
Power, kW Record (target range, 30–34
Fig. A3.2. Ensure all hoses and fittings on the oil heat
kW)
exchanger are properly connected and secure.
Fuel rate, kg/h (6.2 L engine) 9.00 ± 0.10
8.2.3.1 Do not use brass and copper fittings in the external
Fuel rate, kg/h (6.5 L engine) 9.40 ± 0.10
Fuel temperature, °C 35.0 ± 2.0
oilsystem,astheycaninfluenceusedoilwearmetalsanalyses.
Coolant inlet temperature, °C Record
8.2.4 Engine Cooling System Installation—Asuggested en-
Coolant outlet temperature, °C 120.0 ± 2.0
gine cooling system is shown in Fig. A3.4. Coolant flow rate, L/min Record (target range, 53–61
L/min)
8.2.4.1 Remove the thermostat.
Coolant pressure, kPa Record (target range,
8.2.5 Engine Coolant System Charge—Charge the engine
93–107 kPa)
Main oil gallery temperature, °C 120.0 ± 2.0
with coolant solution mixed to the concentration shown in
Intake air temperature, °C 32.0 ± 2.0
7.1.2.
Exhaust temperature, °C Record
8.2.6 Intake Air System Installation—Install the intake air
Oil sump temperature, °C Record
Intake air pressure, kPa 97.0 ± 1.0
horn and Piezometer ring.
Crankcase pressure, kPa Record
8.2.7 Exhaust System Installation—Installtheexhaustmani-
Exhaust back pressure, kPa 103.0 ± 1.0
folds and the exhaust manifold discharge flanges.
D5966 − 22
TABLE 3 Break-in Sequence, Cyclic Stage
9.3.4 Operate the engine speed at 1000 r/min and no power
5min. Stage
Engine Speed, Engine Torque,
Step Length,
9.3.5 After 5 min, increase the power to 7.5 kW and
r/min N·m
min
maintain the engine speed at 1000 r/min. Maintain this condi-
1 650 (Idle) (0)
tion for 15min. The test time begins 10 min after the
2 max. governed (3800) (0) 1
3 3600 max (310) 1
completion of the 15min warm-up period.
4 2800 max (350) 1
9.3.6 During the 10 min after the warm-up, maintain the
5 2000 max (370) 1
engine speed at 1000 r/min and increase the power until the
6 1450 220 1
fuelconsumptionratemeetsthespecificationshowninTable1. 7 max. governed (3800) (0) 1
8 3600 max (310) 1
Maintain these conditions for the duration of the test.
9 2800 max (350) 1
10 2000 max (370) 1
9.4 Normal Engine Shutdown Procedure—Unless an emer-
11 1450 (220) 1
gency condition exists, each time the engine is shutdown, use
12 max governed (3800) (0) 2
the following procedure.
13 3600 max (310) 2
14 2800 max (350) 2
9.4.1 Reduce the engine power to 0 kW.
15 2000 full (370) 2
9.4.2 Operate the engine for 5 min.
16 1450 (220) 2
9.4.3 Stop the engine.
17 650 (Idle) (0) 2
9.5 Emergency Shutdown Procedure—If an emergency con-
dition exists, shut off the fuel supply and stop the engine.
9.7.3.2 Operate the engine according to the steady state
9.6 Unscheduled Shutdowns and Downtime—The test can
sequence shown in Table 2.
be shut down at any convenient time to perform unscheduled
9.7.3.3 Operate the engine according to the cyclic sequence
maintenance.ReportallunscheduledshutdownsonForm19of
shown in Table 3. Except for speed and torque, use the targets
the final test report.
shown in Table 4 for all other controller set points.Total cycle
9.6.1 Resumption of Test Time After a Shutdown—After a
length is 30 min (a cycle includes Steps 2 through 17). Each
shutdown, test time begins 10 min after the completion of the
transition is 30 s in length. Steps 2 through 11 are 60 s each;
15 min period at 7.5 kW in 9.3.5.
Steps12through17are120seach.Repeatthecycle100times
9.7 New Engine Break-in—The break-in provides an oppor-
to complete the cyclic portion of the break-in in 50 h.
tunity to stabilize a new engine and is only performed after a
9.7.3.4 Theenginewillnotmaintainspecificationsforsome
new engine has been installed on the test stand and prior to a
oftheparametersshowninTable4especiallyduringthecyclic
reference test. The break-in is not performed before each 50 h
stage. Controller set points should be maintained at the
non-reference test.
specifications shown in Table 4 for all parameters except
9.7.1 The break-in is comprised of two stages—a stepped,
engine speed and torque.
steady state stage and a cyclic stage. Table 2 describes the
9.7.3.5 The engine will consume oil during the cyclic
steady state stage. The cyclic portion is described in Table 3
portion of the break-in.An engine will normally consume 1 L
(see 9.7.3.3 and 9.7.3.4).
of oil/16 h of break-in operation. Approximately 1 L of oil
9.7.1.1 Use the lifters that are included in the assembled
should be added during Step 17 at 17 h and 34 h.
engine for the engine break-in.
9.8 Pretest Procedure—Theenginepretestprocedureallows
9.7.2 New Engine Break-in Oil Charge:
an opportunity to charge the crankcase with test oil, verify
9.7.2.1 Install a new AC PF-35 oil filter.
injection timing, check the crankcase dipstick level and install
9.7.2.2 Connect the flush system outlet to the oil cooler.
test lifters (roller followers). Complete the pretest procedure
9.7.2.3 Use the flush system to charge 6.5 kg of break-in oil
beforerunningeachsteadystatereferenceornon-referencetest
into the engine.
for 50 h.
NOTE 2—Break-in oil is defined in 7.1.5.
9.7.2.4 Remove the flush system outlet hose from the oil
TABLE 4 Break-in Operating Targets, Steady State and Cyclic
A
Stages
cooler and cap the oil cooler fitting.
9.7.3 New Engine Break-in Operating Procedure: Controlled Parameter Specification
Engine speed, r/min see Tables 1 and 2
9.7.3.1 Start the engine according to 9.3.
Torque, N·m see Tables 1 and 2
Power, kW Record
Fuel temperature, °C 35 ± 2
A Coolant inlet temperature, °C Record
TABLE 2 Break-in Sequence, Steady State Stage
Coolant outlet temperature, °C 120 ± 2
Step Engine Speed, r/min Engine Torque, N·m Time, min
Coolant flow rate, L/min 190 ± 8
1 1000 120 30 Coolant pressure, kPa 100 ± 7
2 2000 140 30 Main oil gallery pressure, kPa Record
3 3000 180 30 Main oil gallery temperature, °C 120 ± 2
4 3600 200 30 Intake air temperature, °C 32 ± 2
5 3800 0 30 Exhaust temperature, °C Record
6 3000 max 30 Oil sump temperature, °C Record
A A
See Table 4 for remaining steady state break-in specifications. The retention of break-in data is at the discretion of the laboratory.
D5966 − 22
9.8.1 The laboratory ambient atmosphere shall be reason- 9.8.6 Calibration of the TDC Indicator—Verifying the cali-
ably free of contaminants. Temperature and humidity level of bration of theTDC indicator located on the harmonic balancer
the operating area are not specified. Divert air from fans or is recommended.
ventilation systems away from the test engine. 9.8.7 Verification of Injection Timing—Start the engine ac-
9.8.2 Initial Test Oil Flush and Lifter Installation: cording to 9.3. After the engine speed and fuel rate have
stabilized at the specifications shown in Table 1, verify the
9.8.2.1 Weigh and install a new AC PF-35 oil filter.
injection timing is 11.5 6 0.5 using the default settings on the
9.8.2.2 Connect the flush system inlet to the fitting on the
timing meter. If the injection timing is outside this
bottom of the oil pan.
specification, rotate the injection pump and remeasure the
9.8.2.3 Connect the flush system outlet to the external oil
timing.
cooler inlet.
9.9 Fifty-Hour Steady State Test—Starttheengineaccording
9.8.2.4 Charge 6.0 kg of test oil into the engine. Record the
actual weight of the oil charge. to 9.3. Operate the engine at the steady state conditions noted
in Table 1 for 50 h.
9.8.2.5 Circulate the oil with the flush system for 15 min.
9.8.2.6 Drain and weigh the oil from the engine. Remove,
9.10 Periodic Measurements:
weigh, and discard the oil filter.
9.10.1 Operational Data Acquisition—Record the opera-
9.8.2.7 Install a new set of hydraulic lifters in the engine
tional parameters shown in Table 1 (with the exception of
positionnotedontherollerfollowershaft.Orientthehydraulic
coolant flow rate and coolant pressure) with automated data
lifters so that the oil hole faces the front of the engine.
acquisition at a minimum frequency of once every 6 min.
9.10.2 Injection Timing Measurement—Measure and record
NOTE3—Adescriptionofthemarkingsontheendoftherollerfollower
the injection timing at least once every test.
shafts is shown in Fig. A6.1.
NOTE 4—Amap of hydraulic lifter positions in the engine is shown in
9.11 Oil Sampling and Oil Addition Procedures—Take used
Fig. A3.4.
oilsamplesat25hand50handaddoilat25h.Makenoother
9.8.2.8 Install the hydraulic lifter guide and hold down
new oil additions or samples during the test.The sampling and
plates. Torque the hold down plates to 35 N·m.
new oil addition procedures are detailed below.
9.8.2.9 Install the push rods and rocker arm assemblies in
9.11.1 Twenty-Five-Hour Oil Sampling and Oil Addition
the engine locations marked on the parts. Torque the rocker
Procedure:
arm shafts to 50 N·m. Refer to the GM Diesel Engine service
NOTE 5—The engine is not shut down for oil addition or oil sampling
manual (GM 16015.05-2) for proper installation.
at 25 h.
9.8.3 Second Test Oil Flush:
9.11.1.1 Weigh 1.0 kg of new oil into a beaker.
9.8.3.1 Weigh and install a new test oil filter.
9.11.1.2 Remove a 100 mL purge from the engine. Then
9.8.3.2 Charge 6.0 kg of test oil into the engine by way of
remove a 100 mL analysis sample from the engine. Label the
the flush system. Record the actual mass of the oil charge.
sample bottle for identification with the test number, date, test
9.8.3.3 Install the rocker arm cover lids.
hour, and oil code.
9.8.3.4 Circulate the oil with the flush cart for 15 min.
9.11.1.3 Pour the 1.0 kg of new test oil and the 100 mL
9.8.3.5 After the oil has circulated for 5 min, crank the
purge into the engine.
engine for a minimum of 2 min. Leave the flush system on
9.11.2 Fifty-Hour Oil Sampling Procedure:
while the engine is cranked.
NOTE 6—The engine is not shut down for oil sampling at 50 h.
9.8.3.6 Drain and weigh the oil from the engine. Remove,
weigh, and discard the oil filter.
9.11.2.1 Remove a 100 mLpurge from the engine. Remove
9.8.4 Test Oil Charge: a 100 mL analysis sample from the engine. Label the sample
bottle for identification with the test number, date, test hour,
9.8.4.1 Weigh and install new oil filter.
and oil code.
9.8.4.2 Disconnect the flush system inlet hose from the oil
pan. Install the cap on the oil pan fitting.
9.12 End of Test (EOT) Procedure:
9.8.4.3 Use the flush system to charge 6.0 kg of test oil into
9.12.1 Engine Oil Removal—Drain the oil from the sump
theengine.Turnofftheflushsystembeforetheinlethosepicks
within 60 min of EOT.
up air.
9.12.2 Solvent Flush:
9.8.4.4 Remove the flush system outlet hose from the oil
9.12.2.1 Charge approximately 7L of solvent into the en-
cooler.Installthecapontheoilcoolerfitting.Becarefulnotto
gine by way of the flush system.
lose any portion of the test oil charge.
9.12.2.2 Circulate the solvent with the flush system for
9.8.4.5 Purge the flush system into a container and pour all
20min. While the solvent is circulating through the engine,
purged oil into the engine.
rotatetheenginetwocompleterevolutionsbyhandtoflushthe
9.8.4.6 After a minimum of 2 min, check the oil level with valve train assembly.
the dipstick. The oil level should be at or near the full mark.
9.12.2.3 Disconnect the flush system, and drain the solvent
9.8.5 Installation of the Crankcase Pressure Transducer— from the engine. If the engine is going to be laid up, flush and
Remove the dipstick and install the line leading to the draintheenginewitha15W40APICG-4qualityoiltoprevent
crankcase pressure transducer to the dipstick tube. rusting.
D5966 − 22
9.12.3 Lifter Removal—Remove the lids from the rocker 11. Final Test Report
arm covers and remove the lifters from the engine.
11.1 Reporting Calibration Test Results—Reportallcalibra-
9.12.4 Roller Follower Shaft Removal—Remove the axle
tion (reference oil) tests to the TMC within five days of test
from the lifter body by pressing the shaft from the body.
completion using the standardized report forms and data
dictionary that are available on the ASTM Test Monitoring
10. Calculation and Interpretation of Test Results
Center web page at http://www.astmtmc.org. Electronic trans-
10.1 Environment of Parts Measurement Area—The ambi-
fer of the test report can be done using the ASTM Data
ent atmosphere of the parts measurement area shall be reason-
Communications Committee Test Report Transmission Model
ably free of contaminants. Maintain the temperature within
(see Section 2—Flat FileTransmission Format) available from
63.0°C of the temperature of the area when the machines
the ASTM TMC. A copy of the final test report (all forms)
were calibrated.
shouldbesubmittedbymailtothetestdeveloperandtheTMC
within 30 days of test completion (see A9.1).
10.2 Roller Follower Shaft Wear Measurements—Measure
and record the shape of the wear scar using a skidless stylus
11.2 Report Forms—For reference oil test, the standardized
type measuring device. Make the measurement with the
reportformsetanddatadictionaryforreportingtestresultsand
reference line etched on the end of the roller follower shaft in
for summarizing the operational data are required. The list of
a vertical position in the measuring device. Calculate the wear
final report forms is shown in Annex A5.
from the wear trace chart. In this test, wear for a given shaft is
11.2.1 Electronic Data Transmission of Test Results—
definedasthemaximumverticaldepthshownontheweartrace
Annex A5 contains the RFWT and Header Data dictionaries.
chart. An example of a typical wear trace and wear determi-
Additional information is also provided for its use. This
nation is shown in Fig. A6.2. Record the calculated wear and
information is provided to anyone wishing to transmit test
corresponding lifter position number.
information electronically. For more information on electronic
10.3 Oil Analysis: transmissions, contact the TMC.
10.3.1 Wear Metals—MeasureAl,Cr,Cu,Fe,Pb,Si,andSn
11.3 Interim Non-Valid Calibration Test Summary—This
contentonoilsamplesat0h(newoilfromcontainer),25hand
information includes test run number, test start and completion
50 h. Test Method D5185 is recommended.
dates, the blind oil code, the industry oil code, the reason the
10.3.2 Viscosity—Measure kinematic viscosity at 100 °C on
test was not acceptable, the corrective action, and any other
oil samples from 0 h (new oil), 25 h and 50 h in accordance
pertinent information. Include this information in the com-
with Annex A7.
ments section of Form 19. Include a comment for each
10.3.3 Soot Quantity—Determinethesootquantity,mass%,
non-valid or aborted calibration test in a series.
onoilsamplesfrom0h(newoil),25hand50hinaccordance
with Annex A8. 11.4 Severity Adjustments—This test incorporates the use of
a Severity Adjustment (SA) for non-reference test results. A
10.4 Assessment of Test Validity—Specific requirements to
control chart technique, described in 11.4.1 and 11.4.2, has
determine test validity status are shown in Table 5.The testing
been selected for the purpose of identifying when a bias
laboratoryshalluseengineeringjudgmenttoassessthevalidity
becomes significant for Roller Follower Shaft Wear. When a
of tests which have deviations from the items listed in Table 5.
significant bias is identified, a SA is applied to non-reference
TheTMC will assist the laboratory in the determination of test
test results. The SAremains in effect until subsequent calibra-
validity, if requested by the laboratory. The mean of each
tion test results indicate that the bias is no longer significant.
parameter listed below, except injection timing, shall fall
SAs are calculated and applied on a laboratory basis.
within the ranges listed below.
11.4.1 Control Chart Technique For Severity Adjustments
10.5 Measure injection timing only once per test. All other
(SA)—Standardizedcalibrationtestresultsareappliedusingan
parameters are measured at least once per 6 min.
exponentially weighted moving average (EWMA) technique.
10.6 All instrumentation shall be calibrated in accordance
Values are standardized to delta/s (result—target)/standard
with Table A4.1. deviation). The targets and standard deviations for current
calibration oils are published by the ASTM TMC. Include all
operationally valid calibration tests in a laboratory control
chart.Charttestsinorderofcompletion.Recordcompletionof
tests by EOT date and time. EOT time is reported as hour and
TABLE 5 Operational Validity Requirements
minute (Central Time) according to the 24 h clock (1
Parameter Specification
am=1:00, 1 pm=13:00). Reporting test completion time
Speed, r/min 1000±5
Fuel rate, kg/h (6.2 L engine) 9.0±0.10
enables the TMC to properly order tests that are completed on
Fuel rate, kg/h (6.5 L engine) 9.40±0.10
the same day for industry plotting purposes. Report calibration
Fuel temperature, °C 35.0±2.0
tests to the TMC in order of test completion. A minimum of
Coolant outlet temperature, °C 120.0±2.0
Main oil gallery temperature, °C 120.0±2.0
two tests is required to initialize a control chart.
Intake air temperature, °C 32.0±2.0
11.4.2 Calculate EWMA values using the following equa-
Intake air pressure, kPa 97.0±1.0
Exhaust back pressure, kPa 103.0±1.0 tion:
Injection timing, °BTDC 11.5±0.5
Z 50.2~Y !10.8 Z (1)
~ !
i i i21
D5966 − 22
rather than repeatability which defines more rigorous within-laboratory
where:
conditions.
Z =0,
12.1.1.1 Intermediate Precision Limit (i.p.)—The difference
Y = standardized test result, and
i
Z = EWMA of the standardized test result at test order i. between two results obtained under intermediate precision
conditions that would, in the long run, in the normal and
IftheabsolutevalueofEWMA,roundedtothreeplacesafter
correct conduct of the test method, exceed the values shown in
the decimal, exceeds 0.600 then apply an SA to subsequent
Table 6 in only one case in twenty. When only a single test
non-reference results.
resultisavailable,theIntermediatePrecisionLimitcanbeused
11.4.3 Calculation of Severity Adjustment—The following
tocalculatearange(testresult 6IntermediatePrecisionLimit)
example illustrates how to compute and apply EWMAand SA
outside of which a second test result would be expected to fall
values.Pleasenote,thattesttargetsarepresentedforexamples
about one time in twenty.
only.
12.1.1.2 Reproducibility Conditions—Conditions where test
Roller Follower Shaft Wear SA
results are obtained with the same test method using the same
TMC Oil 1004
test oil in different laboratories with different operators using
Applicable Test Targets:
different equipment.
Mean=0.41
12.1.1.3 Reproducibility Limit (R)—The difference between
Standard Deviation=0.07
two results obtained under reproducibility conditions that
Z =−0.400
would,inthelongrun,inthenormalandcorrectconductofthe
Test Result:
test method, exceed the values shown in Table 6 in only one
T =0.30
case in twenty. When only a single test result is available, the
Standard Test Result:
Reproducibility Limit can be used to calculate a range (test
Y =(Ti−Mean)⁄Standard Deviation=−1.571
result 6 Reproducibility Limit) outside of which a second test
EWMA: Z =0.2(Y2)+0.8(Z1)=−0.634
result would be expected to fall about one time in twenty.
11.4.3.1 Since ǁ−0.634ǁ > 0.600, apply an SA: SA=(−1)
(EWMA) (standard deviation). Round this result to two deci- 12.2 Precision Estimate—Test precision, as of June 23,
mal places. Enter this number on Form 1 under the non-
2006, is shown in Table 6.
reference oil test block in the space for severity adjustment.
12.3 Bias—Bias is determined by applying a defined statis-
Addthisvaluetonon-referenceaveragewearresults.Enterthe
tical technique to calibration test results. When a significant
adjusted wear value in the appropriate space. An SA will
bias is determined, a severity adjustment is applied to the
remain in effect until the next calibration test. At that time,
non-reference oil test result.
calculate a new EWMA.
13. Keywords
12. Precision and Bias
13.1 calibrate; diesel engine; engine oil; light-duty; light-
12.1 Precision—Test precision is established on the basis of
dutyengine;lubricant;referenceoil;rollerfollowershaftwear;
operationally valid reference oil test results monitored by the
used oil wear
TMC.
12.1.1 Intermediate Precision Conditions—Conditions
TABLE 6 Test Precision
wheretestresultsareobtainedwiththesametestmethodusing
Intermediate
the same test oil, with changing conditions such as operators,
Parameter Precision Reproducibility ( R)
measuring equipment, test stands, test engines, and time. (i.p.)
Roller follower wear 0.13 0.14
NOTE 7—Intermediate precision is the appropriate term for the method,
ANNEXES
(Mandatory Information)
A1. GUIDELINES FOR TEST PART SUBSTITUTION OR MODIFICATION
A1.1 Engine Component Modifications—No modifications supplier listed in Appendix X1.
are allowed to bring any engine component within a specifi-
A1.3 Substitution or Modification of Auxiliary Test Stand
cation or cause a part to operate within a specification.
Equipment—Substitutions or modifications of auxil-
A1.2 Test Part Substitution—Obtain all lifters and engines iary test stand equipment are only allowed where explicitly
usedfromthesupplierlistedinAppendixX1.Obtainoilfilters stated or if the word suggested is used to describe a modifica-
used in the 50 h, steady state portion of the test from the tion or component.
D5966 − 22
A2. GUIDELINES FOR UNITS AND SPECIFICATION FORMATS
A2.1 Significant Digits—Theappropriatenumberofsignifi- A2.2 Units for Measurements and Unit Conversions—All
cant digits for each operational parameter is shown in Table dimensions have been specified with rounded, convenient SI
A2.1.Reportoperationaldataandwearmeasurementusingthe
values where possible. The intent of this procedure is to cause
number of significant digits specified in Table A2.1.
all measurements to be completed directly in appropriate SI
units.
A2.1.1 The following information applies to all specified
limits in this standard. For purposes of determining confor-
A2.3 Units for Reporting Results—All data except roller
mance with these specifications, an observed value or a
follower shaft wear should be reported in appropriate SI units.
calculated value shall be rounded off to the nearest unit in the
last right hand figure used in expressing the limiting value in
A2.4 Specification Formats—Specifications are listed in
TableA2.1.Thisisinaccordancewiththerounding-offmethod
three different formats throughout the standard. Specifications
of Practice E29.
which have a target and no tolerance are listed as x.xxx. For
example, torque specifications are listed as 40 N·m. Specifica-
TABLE A2.1 Significant Digits for Operating Conditions
tions which have a target and a tolerance are listed as xx.xx 6
Parameter Round off to Nearest
x.xx. For example, engine speed is (1000 6 5)r⁄min. Speci-
Speed 1 r/min
ficationswhichhaverangesbutnotargetareusedwhen(1)the
Torque 1 N·m
Power 0.1 kW
value of the parameter is not critical as long as the parameter
Fuel rate 0.01 kg/h
is within the range specified or (2) the measurement technique
Fuel temperature 0.1 °C
Coolant inlet temperature 0.1 °C is not precise.
Coolant outlet temperature 0.1 °C
Coolant flow rate 1 L/min A2.4.1 Specificationswithatargetimplythecorrectvalueis
Coolant pressure 1 kPa
the target and the mean of a random sample representing the
Main oil gallery temperature 0.1 °C
parameter should be equivalent to the target. The range is
Intake air temperature 0.1 °C
Exhaust temperature 0.1 °C
intended as a guide for maximum acceptable variation around
Oil sump temperature 0.1 °C
the mean. Operation within the range specified does not imply
Intake air pressure 0.1 kPa
Crankcase pressure 0.01 kPa
that the parameter will not bias the final test results.
Exhaust back pressure 0.1 kPa
A2.4.1.1 Do not intentionally calibrate or control a param-
Injection timing 0.1°BTDC
Significant Digits for Wear Results eter with a target at a level other than the target.
Parameter Round off to nearest
Roller follower shaft wear 0.00001 in.
A3. DETAILED SPECIFICATIONS OF THE APPARATUS
A3.1 The test engine is based on the General Motor Corpo- Detailed description of the apparatus is grouped into the
ration’s V8 indirect injection diesel engine. Assemble the test following sections:
engineusingmodifiedcylinderheadsandanindividuallytimed
A3.6.1 The Test Engine—Paragraph A3.7.
injection pump.
A3.6.2 Control Systems—Paragraph A3.8.
A3.2 Use an engine test stand equipped to control engine
speed and torque, and various temperatures, pressures, and
A3.6.3 Measurement Transducers and Systems—Paragraph
flow rates.
A3.9.
A3.3 Use an automated data acquisition system to measure
A3.7 Test Engine
various operating parameters.
A3.7.1 Test Engine Kit—Obtain the engine kit from the
A3.4 Useexternalsystemstocontrolengineintakeair,fuel, supplier listed in A9.1.3 which contains all the necessary
coolant, and oil temperatures and pressures. consumable hardware for fifteen tests.Acomplete list of parts
included in the kit is shown in Tables A3.1 and A3.2.
A3.5 Variousexternalapparatusarerequiredtomeasureand
A3.7.1.1 Critical Parts—Acritical part is any part that will
calibrate engine components, control systems, and operating
impact combustion (fuel rate, injection timing, compression
parameters.
ratio, air flow, and oil consumption) or roller follower lubrica-
A3.6 Organization of Apparatus Description Sections— tion and loading (see Table A3.1).
D5966 − 22
TABLE A3.1 Critical Parts
isdescribedinA3.7.3.1–A3.7.3.4.Itemsroutinelyusedinthe
Part No. Description laboratory and workshop are not included.
Engine assembly (6.2 or 6.5 L HD NA C/K) A3.7.3.1 Injection Timing Measurement—Measureinjection
Short block assembly
timing using the indicator located on the harmonic balancer.
...