ASTM D6975-2004 Standard Test Method for Cummins M11 EGR Test《康明斯发动机M11排气再循环试验的标准试验方法》.pdf

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1、Designation: D 6975 04An American National StandardStandard Test Method forCummins M11 EGR Test1This standard is issued under the fixed designation D 6975; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision.

2、A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method is commonly referred to as the Cum-mins M11 Exhaust Gas Recirculation Test (EGR). The testmethod defines a heavy-du

3、ty diesel engine test procedureconducted under high soot conditions to evaluate oil perfor-mance with regard to valve train wear, sludge deposits, and oilfilter plugging2in an EGR environment.1.2 The values stated in SI units are to be regarded as thestandard. The values given in parentheses are for

4、 informationonly.1.3 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to us

5、e. See Annex A1 forgeneral safety precautions.1.4 Table of Contents:Scope 1Referenced Documents 2Terminology 3Summary of Test Method 4Significance and Use 5Apparatus 6Test Engine Configuration 6.1Test Engine 6.1.1Oil Heat Exchanger, Adapter Blocks, andBlock Off Plate6.1.2Oil Filter Head Modification

6、 6.1.3Oil Pan Modification 6.1.4Engine Control Module 6.1.5Engine Position Sensor 6.1.6Air Compressor and Fuel Pump 6.1.7Test Stand Configuration 6.2Engine Mounting 6.2.1Intake Air System 6.2.2Aftercooler 6.2.3Exhaust System 6.2.4Exhaust Gas Recirculation System 6.2.5Fuel Supply 6.2.6Coolant System

7、6.2.7Pressurized Oil Fill System 6.2.8External Oil System 6.2.9Crankcase Aspiration 6.2.10Blowby Rate 6.2.11System Time Responses 6.3Oil Sample Containers 6.4Mass Balance 6.5Engine and Cleaning Fluids 7Test Oil 7.1Test Fuel 7.2Engine Coolant 7.3Solvent 7.4Preparation of Apparatus 8Cleaning of Parts

8、8.1General 8.1.1Engine Block 8.1.2Cylinder Head 8.1.3Rocker Cover and Oil Pan 8.1.4External Oil System 8.1.5Crosshead Cleaning and Measurement 8.1.6Rod Bearing Cleaning and Measurement 8.1.7Ring Cleaning and Measurement 8.1.8Injector Adjusting Screw Cleaning and Measurement 8.1.9Engine Assembly 8.2G

9、eneral 8.2.1Parts Reuse and Replacement 8.2.2Build-Up Oil 8.2.3Coolant Thermostat 8.2.4Oil Thermostat 8.2.5Fuel Injectors 8.2.6New Parts 8.2.7Operational Measurements 8.3Units and Formats 8.3.1Instrumentation Calibration 8.3.2Temperatures 8.3.3Pressures 8.3.4Flow Rates 8.3.5Intake and Exhaust CO2Mea

10、surement 8.3.6Engine/Stand Calibration and Non-Reference Oil Tests 9General 9.1New Test Stand 9.2New Test Stand Calibration 9.2.1Stand Calibration Period 9.3Stand Modification and Calibration Status 9.4Test Numbering System 9.5General 9.5.1Reference Oil Tests 9.5.2Non-Reference Oil Tests 9.5.3Refere

11、nce Oil Test Acceptance 9.6Unacceptable Reference Oil Test 9.7Reference Oil Accountability 9.8Non-Reference Oil Tests 9.9Last Start Date 9.9.2Test Procedure 10Engine Installation and Stand Connections 10.1Coolant System Fill 10.2Oil Fill for Break-in 10.3Engine Build Committed 10.3.31This test metho

12、d is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct responsibility of SubcommitteeD02.B0 on Automotive Lubricants.Current edition approved Nov. 1, 2004. Published November 2004. Originallyapproved in 2003. Last previous edition approved in 2003 as

13、D 697503.2The ASTM Test Monitoring Center will update changes in this test method bymeans of Information Letters. Information letters may be obtained from the ASTMTest Monitoring Center, 6555 Penn Avenue, Pittsburgh, PA 15206-4489, Attention:Administrator. This edition incorporates revisions contain

14、ed in all informationletters through 03-1.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.Fuel Samples 10.4Engine Warm-up 10.5Shutdown During Warm-up 10.5.1Engine Break-in 10.6Shutdown and Maintenance 10.7Normal Shutdown 10.7.1Emerge

15、ncy Shutdown 10.7.2Maintenance 10.7.3Downtime 10.7.4300-h Test Procedure 10.8Oil Fill for Test 10.8.2Operating Conditions 10.8.4Injection Timing Change 10.8.5Mass % Soot Validity 10.8.6Test Timer 10.8.7Operational Data Acquisition 10.8.8Oil Purge, Sample and Addition 10.8.9End of Test (EOT) 10.9Engi

16、ne Disassembly 10.9.4Calculations, Ratings, and Test Validity 11Crosshead Mass Loss 11.1Injector Adjusting Screw Mass Loss 11.2Rod Bearing Mass Loss 11.3Ring Mass Loss 11.4Sludge Ratings 11.5Piston Ratings 11.6Oil Filter Plugging 11.7Oil Analyses 11.8Oil Consumption 11.9Fuel Analyses 11.10Assessment

17、 of Operational Validity 11.11Assessment of Test Interpretability 11.12Test Report 12Precision and Bias 13Keywords 14AnnexesSafety Precautions Annex A1Intake Air Aftercooler Annex A2Engine Build Parts Kit Annex A3Sensor Locations and Special Hardware Annex A4External Oil System Annex A5Fuel Specific

18、ation Annex A6Cummins Service Publications Annex A7Specified Units and Formats Annex A8Report Forms and Data Dictionary Annex A9Sludge Rating Worksheets Annex A10Piston Rating Locations Annex A11Oil Analyses Annex A12Oil Filter Plugging Annex A13Determination of Operational Validity Annex A14Exhaust

19、 CO2Sampling Probe Annex A15AppendixTypical System Configurations Appendix X12. Referenced Documents2.1 ASTM Standards:3D 86 Test Method for Distillation of Petroleum Products atAtmospheric PressureD 92 Test Method for Flash and Fire Points by ClevelandOpen Cup TesterD 97 Test Method for Pour Point

20、of Petroleum ProductsD 129 Test Method for Sulfur in Petroleum Products (Gen-eral Bomb Method)D 130 Test Method for Corrosiveness to Copper fromPetroleum Products by Copper Strip TestD 287 Test Method forAPI Gravity of Crude Petroleum andPetroleum Products (Hydrometer Method)D 445 Test Method for Ki

21、nematic Viscosity of Transparentand Opaque Liquids (and the Calculation of DynamicViscosity)D 482 Test Method for Ash from Petroleum ProductsD 524 Test Method for Ramsbottom Carbon Residue ofPetroleum ProductsD 613 Test Method for Cetane Number of Diesel Fuel OilD 664 Test Method forAcid Number of P

22、etroleum Productsby Potentiometric TitrationD 976 Test Methods for Calculated Cetane Index of Distil-late FuelsD 1319 Test Method for Hydrocarbon Types in LiquidPetroleum Products by Fluorescent Indicator AbsorptionD 2274 Test Method for Oxidation Stability of DistillateFuel Oil (Accelerated Method)

23、D 2500 Test Method for Cloud Point of Petroleum ProductsD 2622 Test Method for Sulfur in Petroleum Products byWavelength Dispersive X-ray Fluorescence SpectrometryD 2709 Test Method for Water and Sediment in MiddleDistillate Fuels by CentrifugeD 2896 Test Method for Base Number of Petroleum Prod-uct

24、s by Potentiometric Perchloric Acid TitrationD 4052 Test Method for Density and Relative Density ofLiquids by Digital Density MeterD 4485 Specification for Performance of Engine OilsD 4737 Test Method for Calculated Cetane Index by FourVariable EquationD 4739 Test Method for Base Number Determinatio

25、n byPotentiometric TitrationD 5185 Test Method for Determination of Additive Ele-ments, Wear Metals, and Contaminants in Used Lubricat-ing Oils and Determination of Selected Elements in BaseOils by Inductively Coupled Plasma Atomic EmissionSpectrometry (ICP-AES)D 5302 Test Method for Evaluation of A

26、utomotive EngineOils for Inhibition of Deposit Formation and Wear in aSpark-Ignition Internal Combustion Engine Fueled withGasoline and Operated Under Low-Temperature, LightDuty Conditions4D 5844 Test Method for Evaluation of Automotive EngineOils for Inhibition of Rusting (Sequence IID)4D 5967 Test

27、 Method for Evaluation of Diesel Engine Oils inT-8 Diesel EngineD 6483 Test Method for Evaluation of Diesel Engine Oils inT-9 Diesel EngineD 6557 Test Method for Evaluation of Rust PreventiveCharacteristics of Automotive Engine OilsE 29 Practice for Using Significant Digits in Test Data toDetermine

28、Conformance with SpecificationsE 344 Terminology Relating to Thermometry and Hydrom-etry2.2 Coordinating Research Council (CRC):5CRC Manual No. 203For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards

29、 volume information, refer to the standards Document Summary page onthe ASTM website.4Withdrawn.5Available from the Coordinating Research Council, Inc., 219 PerimeterParkway, Atlanta, GA 30346.D69750422.3 National Archives and Records Administration:6Code of Federal Regulations Title 40 Part 86.310-

30、793. Terminology3.1 Definitions:3.1.1 blind reference oil, na reference oil, the identity ofwhich is unknown by the test facility. D 58443.1.2 blowby, nin internal combustion engines, the com-bustion products and unburned air-and-fuel mixture that enterthe crankcase. D 53023.1.3 calibrate, vto deter

31、mine the indication or output ofa measuring device with respect to that of a standard. E 3443.1.4 heavy-duty, adjin internal combustion engine op-eration, characterized by average speeds, power output, andinternal temperatures that are close to the potential maximum.D 44853.1.5 heavy-duty engine, ad

32、jin internal combustion en-gines, one that is designed to allow operation continuously ator close to its peak output. D 44853.1.6 non-reference oil, nany oil other than a referenceoil, such as a research formulation, commercial oil, or candi-date oil. D 58443.1.7 non-standard test, na test that is n

33、ot conducted inconformance with the requirements in the standard testmethod; such as running in a non-calibrated test stand or usingdifferent test equipment, applying different equipment assem-bly procedures, or using modified operating conditions.D 58443.1.8 reference oil, nan oil of known performa

34、nce char-acteristics used as a basis for comparison. D 44853.1.9 sludge, nin internal combustion engines, a deposit,principally composed of insoluble resins and oxidation prod-ucts from fuel combustion and the lubricant, that does not drainfrom engine parts but can be removed by wiping with a cloth.

35、D 53023.1.10 test oil, nany oil subjected to evaluation in anestablished procedure. D 65573.1.11 wear, nthe loss of material from, or relocation ofmaterial on, a surface. D 53023.1.11.1 DiscussionWear generally occurs between twosurfaces moving relative to each other, and is the result ofmechanical

36、or chemical action or by a combination of me-chanical and chemical actions.3.2 Definitions of Terms Specific to This Standard:3.2.1 crosshead, nan overhead component, located be-tween the rocker arm and each intake valve and exhaust valvepair, that transfers rocker arm travel to the opening and clos

37、ingof each valve pair.3.2.1.1 DiscussionEach cylinder has two crossheads, onefor each pair of intake valves and exhaust valves.3.2.2 de-rate protocols, nprotocols in the engine controlmodule that cause the engine to reduce power output whencertain operating parameters are exceeded.3.2.3 exhaust gas

38、recirculation (EGR), na method bywhich a portion of the engine exhaust is returned to thecombustion chambers through the intake system.3.2.4 overhead, nin internal combustion engines, thecomponents of the valve train located in or above the cylinderhead.3.2.5 overfuel, vto cause the fuel flow to exc

39、eed thestandard production setting.3.2.6 valve train, nin internal combustion engines, theseries of components, such as valves, crossheads, rocker arms,push rods, and camshaft, that open and close the intake andexhaust valves.4. Summary of Test Method4.1 This test method uses a Cummins M11 400 diese

40、lengine with a specially modified engine block. Test operationincludes a 25-min warm-up, a 2-h break-in, and 300 h in six50-h stages. During stages A, C, and E, the engine is operatedwith retarded fuel injection timing and is overfueled togenerate excess soot. During stages B, D, and F, the engine i

41、soperated at conditions to induce valve train wear.4.2 Prior to each test, the engine is cleaned and assembledwith new cylinder liners, pistons, piston rings, and overheadvalve train components. All aspects of the assembly arespecified.4.3 A forced oil drain, an oil sample, and an oil addition,equiv

42、alent to an oil consumption of 0.23 g/kW-h, is performedat the end of each 25-h period.4.4 The test stand is equipped with the appropriate instru-mentation to control engine speed, fuel flow, and other oper-ating parameters.4.5 Oil performance is determined by assessing crossheadwear at 8.5 mass % s

43、oot, sludge deposits, and oil filterplugging.5. Significance and Use5.1 This test method was developed to assess the perfor-mance of an engine oil to control engine wear and depositsunder heavy-duty operating conditions selected to acceleratesoot generation, valve train wear, and deposit formation i

44、n aturbocharged, aftercooled four-stroke-cycle diesel engineequipped with exhaust gas recirculation hardware.5.2 This test method may be used for engine oil specifica-tion acceptance when all details of this test method are incompliance. Applicable engine oil service categories are in-cluded in Spec

45、ification D 4485.5.3 The design of the engine used in this test method isrepresentative of many, but not all, modern diesel engines. Thisfactor, along with the accelerated operating conditions, needsto be considered when extrapolating test results.6. Apparatus6.1 Test Engine Configuration:6.1.1 Test

46、 EngineThe Cummins M11 400 is an in-linesix-cylinder heavy-duty diesel engine with 11 L of displace-ment and is turbocharged and aftercooled. The engine has anoverhead valve configuration and EGR hardware. It features a1994 emissions configuration with electronic control of fuel6Available from Super

47、intendent of Documents, Attn: New Orders, P.O. Box371954, Pittsburgh, PA 15250-7954.D6975043metering and fuel injection timing. Obtain the test engine, theengine build parts kit, and non-kit parts from the central partsdistributor (CPD).7,8The components of the engine build partskit are shown in Tab

48、le A3.1. Non-kit parts are shown in TableA3.2.6.1.2 Oil Heat Exchanger, Adapter Blocks, and Block-OffPlateThe oil heat exchanger is relocated from the stockposition with the use of adapter blocks as shown in Fig.A4.1.8,9Install an oil cooler block-off plate on the back of thecoolant thermostat housi

49、ng (Fig. A4.1). Control the oil tem-perature by directing engine coolant through the oil heatexchanger (Fig. A4.2).6.1.3 Oil Filter Head ModificationModify the oil filterhead by plugging the filter bypass return to sump line and theengine oil thermostat (Fig.A4.8). Block the thermostat passageto route all of the engine oil into the oil cooler.6.1.4 Oil Pan ModificationModify the oil pan as shown inFig. A4.3.8,96.1.5 Engine Control Module (ECM)Obtain the ECMfrom the CPD.7,8The ECM programming has been modified toprovide overfueling and retarded injection timing