ASTM D7468-2008 781 Standard Test Method for Cummins ISM Test.pdf

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1、Designation: D 7468 08Standard Test Method forCummins ISM Test1This standard is issued under the fixed designation D 7468; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A number in parentheses indicates

2、 the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 The test method covers a heavy-duty diesel engine testprocedure conducted under high soot conditions to evaluate oilperformance with regard to valve train wear, top r

3、ing wear,sludge deposits, and oil filter plugging in an EGR environment.This test method is commonly referred to as the Cummins ISMTest.21.2 The values stated in SI units are to be regarded asstandard. No other units of measurement are included in thisstandard.1.2.1 ExceptionThe only exception is wh

4、ere there is nodirect SI equivalent such as screw threads, national pipethreads/diameters, and tubing sizes.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

5、and health practices and determine the applica-bility of regulatory limitations prior to use. See Annex A1 forgeneral safety precautions.1.4 Table of Contents:SectionScope 1Referenced Documents 2Terminology 3Summary of Test Method 4Significance and Use 5Apparatus 6Test Engine Configuration 6.1Test E

6、ngine 6.1.1Oil Heat Exchanger, Adapter Blocks, Block Off Plate 6.1.2Oil Filter Head Modification 6.1.3Oil Pan Modification 6.1.4Engine Control Module (ECM) 6.1.5Engine Position Sensor 6.1.6Intake Manifold Temperature Sensor 6.1.7Barometric Pressure Sensor 6.1.8Turbocharger Controller 6.1.9Power Supp

7、ly Voltage 6.1.10Air Compressor and Fuel Pump 6.1.11Engine Block Preparation 6.1.12SectionTest 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 System 6.2.6Coolant System 6.2.7Pressurized Oil Fill Syste

8、m 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 7.3Pentane 7.4Solvent 7.5Preparation of Apparatus 8Cleaning of Parts 8.1General 8.1.1Engi

9、ne 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 8.2General 8.2.1Parts Re

10、use 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 CO2Measurement 8.3.6Engine

11、/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 9.5.31This test method is under

12、 the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct responsibility of SubcommitteeD02.B0 on Automotive Lubricants.Current edition approved Dec. 1, 2008. Published March 2009.2The ASTM Test Monitoring Center will update changes in this test method bymeans of

13、Information Letters. Information letters may be obtained from the ASTMTest Monitoring Center, 6555 Penn Avenue, Pittsburgh, PA 15206-4489, Attention:Administrator.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.SectionReference Oil T

14、est Acceptance 9.6Reference Oil Accountability 9.7Last Start Date 9.8Donated Reference Oil Test Programs 9.9Adjustments to Reference Oil Calibration Periods 9.10Procedural Deviations 9.10.1Parts and Fuel Shortages 9.10.2Reference Oil Test Data Flow 9.10.3Special Use of the Reference Oil Calibration

15、System 9.10.4Test Procedure 10Engine Installation and Stand Connections 10.1Coolant System Fill 10.2Oil Fill for Break-in 10.3Engine Build Committed 10.3.3Fuel Samples 10.4Engine Warm-up 10.5Shutdown During Warm-up 10.5.1Engine Break-in 10.6Shutdown and Maintenance 10.7Normal Shutdown 10.7.1Emergenc

16、y Shutdown 10.7.2Maintenance 10.7.3Downtime 10.7.4200-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 Sampling 10.8.9Oil Addition 10.8.10End of Test (EOT) 10.9Engi

17、ne Disassembly 10.9.3Calculations, Ratings and Test Validity 11Crosshead Mass Loss 11.1Crosshead Mass Loss Correction Factor 11.1.8Injector Adjusting Screw Mass Loss 11.2Injector Adjusting Screw Correction Factor 11.2.5Ring Mass Loss 11.3Sludge Ratings 11.4Oil Filter Plugging 11.5Oil Analyses 11.6Oi

18、l Consumption 11.7Fuel Analyses 11.8Additional Analysis 11.8.1Assessment of Operational Validity 11.9Assessment of Test Interpretability 11.10Test Report 12Report Forms 12.1Reference Oil Test 12.2Electronic transmission of Test Results 12.2.1Precision and Bias 13Precision 13.1Intermediate Precision

19、Conditions 13.1.1Reproducibility Conditions 13.1.2Bias 13.2Keywords 14AnnexesSafety Precautions Annex A1Intake Air Aftercooler Annex A2Engine Build Parts Kit Annex A3Sensor Locations, Special Hardware, and Engine BlockModificationsAnnex A4External Oil System Annex A5Fuel Specification Annex A6Cummin

20、s Service Publications Annex A7Specified Units and Formats Annex A8Report Forms and Data Dictionary Annex A9Sludge Rating Worksheets Annex A10Oil Analyses Annex A11Determination of Operational Validity Annex A12Exhaust CO2Sampling Probe Annex A13ISM Merit Rating Calculation Annex A14AppendixTypical

21、System Configurations Appendix X12. Referenced Documents2.1 ASTM Standards:3D86 Test Method for Distillation of Petroleum Products atAtmospheric PressureD93 Test Methods for Flash Point by Pensky-MartensClosed Cup TesterD97 Test Method for Pour Point of Petroleum ProductsD 130 Test Method for Corros

22、iveness to Copper fromPetroleum Products by Copper Strip TestD 235 Specification for Mineral Spirits (Petroleum Spirits)(Hydrocarbon Dry Cleaning Solvent)D 287 Test Method forAPI Gravity of Crude Petroleum andPetroleum Products (Hydrometer Method)D 445 Test Method for Kinematic Viscosity of Transpar

23、entand Opaque Liquids (and Calculation of Dynamic Viscos-ity)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 Petroleum Productsby Potentiomet

24、ric TitrationD 976 Test Method for Calculated Cetane Index of Distil-late FuelsD 1319 Test Method for Hydrocarbon Types in LiquidPetroleum Products by Fluorescent Indicator AdsorptionD 2274 Test Method for Oxidation Stability of DistillateFuel Oil (Accelerated Method)D 2500 Test Method for Cloud Poi

25、nt 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 4052 Test Method for Density and Relative Density ofLiquids by Digital Density MeterD

26、4175 Terminology Relating to Petroleum, PetroleumProducts, and LubricantsD 4294 Test Method for Sulfur in Petroleum and PetroleumProducts by Energy Dispersive X-ray Fluorescence Spec-trometryD 4485 Specification for Performance of Engine OilsD 4737 Test Method for Calculated Cetane Index by FourVari

27、able EquationD 4739 Test Method for Base Number Determination byPotentiometric Hydrochloric Acid 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 Plas

28、ma Atomic EmissionSpectrometry (ICP-AES)D 5453 Test Method for Determination of Total Sulfur inLight Hydrocarbons, Spark Ignition Engine Fuel, Diesel3For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStanda

29、rds volume information, refer to the standards Document Summary page onthe ASTM website.D7468082Engine Fuel, and Engine Oil by Ultraviolet FluorescenceD 5967 Test Method for Evaluation of Diesel Engine Oils inT-8 Diesel EngineE29 Practice for Using Significant Digits in Test Data toDetermine Conform

30、ance with SpecificationsE 178 Practice for Dealing With Outlying ObservationsE 344 Terminology Relating to Thermometry and Hydrom-etry2.2 Coordinating Research Council:4CRC Manual No. 202.3 National Archives and Records Administration:Code of Federal Regulations Title 40 Part 86.310-7953. Terminolog

31、y3.1 Definitions:3.1.1 blind reference oil, na reference oil, the identity ofwhich is unknown by the test facility. D 41753.1.2 blowby, nin internal combustion engines, the com-bustion products and unburned air-and-fuel mixture that enterthe crankcase. D 41753.1.3 calibrate, vto determine the indica

32、tion or output ofa measuring device with respect to that of a standard. E 3443.1.4 exhaust gas recirculation (EGR), na method bywhich a portion of the engine exhaust is returned to thecombustion chambers through the intake system.3.1.5 heavy-duty, adjin internal combustion engine op-eration, charact

33、erized by average speeds, power output, andinternal temperatures that are close to the potential maximum.D 44853.1.6 heavy-duty engine, nin internal combustion en-gines, one that is designed to allow operation continuously ator close to its peak output. D 44853.1.7 non-reference oil, nany oil other

34、than a referenceoil, such as a research formulation, commercial oil or candidateoil. D 41753.1.8 non-standard test, na test that is not conducted inconformance with the requirements in the standard testmethod; such as running in an non-calibrated test stand orusing different test equipment, applying

35、 different equipmentassembly procedures, or using modified operating conditions.D 41753.1.9 reference oil, nan oil of known performance char-acteristics, used as a basis for comparison. D 44853.1.10 sludge, nin internal combustion engines, a deposit,principally composed of insoluble resins and oxida

36、tion prod-ucts from fuel combustion and the lubricant, that does not drainfrom engine parts but can be removed by wiping with a cloth.D 41753.1.11 test oil, nany oil subjected to evaluation in anestablished procedure. D 59673.1.12 valve train, nin internal combustion engines, theseries of components

37、, such as valves, crossheads, rocker arms,push rods, and camshaft, that open and close the intake andexhaust valves.3.1.13 wear, nthe loss of material from a surface, gener-ally occurring between two surfaces in relative motion, andresulting from mechanical or chemical action or a combinationof both

38、.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 closingof each valve pair.3.2.1.1 DiscussionEach cylinder has two crossheads,

39、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 overhead, nin internal combustion engines, thecomponents of the valve train located in

40、 or above the cylinderhead.3.2.4 overfuel, vto cause the fuel flow to exceed thestandard production setting.4. Summary of Test Method4.1 This test method uses a Cummins ISM 500 diesel enginewith a specially modified engine block. Test operation includesa 25-min warm-up, a 2-h break-in, and 200 h in

41、four 50-hstages. During stages A and C the engine is operated withretarded fuel injection timing and is overfueled to generateexcess soot. During stages B and D the engine is operated atconditions to increase valve train wear.4.2 Prior to each test, the engine is cleaned and assembledwith new cylind

42、er 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,equivalent 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

43、appropriate instru-mentation to control engine speed, fuel flow, and other oper-ating parameters.4.5 Oil performance is determined by assessing crossheadwear, top ring mass loss, injector adjusting screw mass loss,sludge deposits, and oil filter plugging.5. Significance and Use5.1 This test method w

44、as 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 in aturbocharged, aftercooled four-stroke-cycle diesel engineequipped with exhaust gas reci

45、rculation 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 Specification D 4485.5.3 The design of the engine used in this test method isrepresentative of

46、 many, but not all, modern diesel engines. This4Available from the Coordinating Research Council, Inc., 219 PerimeterParkway, Atlanta, GA 30346.5Available from Superintendent of Documents, Attn: New Orders, P.O. Box371954, Pittsburgh, PA 15250-7954. Charge orders may be telephoned to theGovernment P

47、rinting Office order desk.D7468083factor, along with the accelerated operating conditions needs tobe considered when extrapolating test results.6. Apparatus6.1 Test Engine Configuration:6.1.1 Test EngineThe Cummins ISM 500 is an in-linesix-cylinder heavy-duty diesel engine with 11 L of displace-ment

48、 and is turbocharged and aftercooled. The engine has anoverhead valve configuration and EGR hardware. It features a2002 emissions configuration with electronic control of fuelmetering and fuel injection timing. Obtain the test engine andthe engine build parts kit from the central parts distributor(C

49、PD).6The components of the engine build parts kit areshown in Table A3.1. Non-kit parts are shown in Table A3.2.6.1.2 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. A4.1.7Install an oil cooler block-off plate on the back of the coolantthermostat housing (Fig. A4.1). Control the oil temperature bydirecting process water through the oil heat exchanger (Fig.A4.1).6.1.3 Oil Filter Head ModificationModify the oil filterhead by plugging the filter bypass re