Scope

1

Referenced Documents

2

Terminology

3

Summary of Test Method

4

Significance and Use

5

Apparatus

6

Test Engine Configuration

6.1

Test Engine

6.1.1

Test Stand Configuration

6.2

Engine Mounting

6.2.1

Intake Air System

6.2.2

Aftercooler

6.2.3

Exhaust System

6.2.4

Fuel System

6.2.5

Coolant System

6.2.6

Oil System

6.2.7

Oil Volume

6.2.7.1

Pressurized Oil Fill System

6.2.7.2

External Oil System

6.2.7.3

Oil Sample Valve Location

6.2.7.4

Unacceptable Oil System Materials

6.2.7.5

Crankcase Aspiration

6.3

Blowby Rate

6.4

System Time Responses

6.5

Clearance Measurements

6.6

Engine and Cleaning Fluids

7

Engine Oil

7.1

Test Fuel

7.2

Test Coolant

7.3

Solvent

7.4

Preparation of Apparatus

8

Cleaning of Parts

8.1

General

8.1.1

Engine Block

8.1.2

Cylinder Head

8.1.3

Rocker Cover and Oil Pan

8.1.4

External Oil System

8.1.5

Rod Bearing Cleaning and Measurement

8.1.6

Ring Cleaning and Measurement

8.1.7

Injector Nozzle

8.1.8

Pistons

8.1.9

Engine Assembly

8.2

General

8.2.1

Parts Reuse and Replacement

8.2.2

Build-Up Oil

8.2.3

Coolant Thermostat

8.2.4

Fuel Injectors

8.2.5

New Parts

8.2.6

Operational Measurements

8.3

Units and Formats

8.3.1

Instrumentation Calibration

8.3.2

Fuel Consumption Rate Measurement Calibration

8.3.2.1

Temperature Measurement Calibration

8.3.2.2

Pressure Measurement Calibration

8.3.2.3

Temperatures

8.3.3

Measurement Location

8.3.3.1

Coolant Out Temperature

8.3.3.2

Coolant In Temperature

8.3.3.3

Fuel In Temperature

8.3.3.4

Oil Gallery Temperature

8.3.3.5

Intake Air Temperature

8.3.3.6

Intake Air after Compressor Temperature

8.3.3.7

Intake Manifold Temperature

8.3.3.8

Exhaust Temperature

8.3.3.9

Exhaust after Turbo Temperature

8.3.3.10

Additional Temperatures

8.3.3.11

Pressures

8.3.4

Measurement Location and Equipment

8.3.4.1

Condensation Trap

8.3.4.2

Coolant Pressure

8.3.4.3

Fuel Pressure

8.3.4.4

Oil Gallery Pressure

8.3.4.5

Intake Air Pressure

8.3.4.6

Intake Air after Compressor Pressure

8.3.4.7

Intake Manifold Pressure

8.3.4.8

Exhaust after Turbo Pressure

8.3.4.9

Crankcase Pressure

8.3.4.10

Additional Pressures

8.3.4.11

Flow Rates

8.3.5

Flow Rate Location and Measurement Equipment

8.3.5.1

Blowby

8.3.5.2

Fuel Flow

8.3.5.3

Engine/Stand Calibration and Non-Reference Coolant
   Tests

9

General

9.1

New Test Stand

9.2

New Test Stand Calibration

9.2.1

Stand Calibration Period

9.3

Stand Modification and Calibration Status

9.4

Test Numbering System

9.5

General

9.5.1

Reference Coolant Tests

9.5.2

Non-Reference Coolant Tests

9.5.3

Reference Coolant Test Acceptance

9.6

Reference Coolant Accountability

9.7

Last Start Date

9.8

Donated Reference Coolant Test Programs

9.9

Adjustments to Reference Coolant Calibration Periods

9.10

Procedure Development

9.10.1

Parts and Fuel Shortages

9.10.2

Reference Coolant Test Data Flow

9.10.3

Special Use of The Reference Coolant Calibration System

9.10.4

Procedure

10

Engine Installation and Stand Connections

10.1

Break-in

10.2

Coolant System Fill for Break-in

10.2.1

Oil Fill for Break-in

10.2.2

Engine Build Committed

10.2.3

Break-in Conditions

10.2.4

Shutdown during Break-in

10.2.5

250-Hour Test Procedure

10.3

Coolant System Fill for Test

10.3.1

Zero-Hour Coolant Sample

10.3.1.1

Oil Fill for Test

10.3.2

Zero-Hour Oil Sample

10.3.2.1

Warm-Up

10.3.3

Warm-up Conditions

10.3.3.1

Shutdown during Warm-up

10.3.3.2

20-Hour Steady State Extended Break-in

10.3.4

20-Hour Steady State Extended Break-in Conditions

10.3.4.1

Shutdown during 20-Hour Extended Break-in

10.3.4.2

230-Hour Cyclic

10.4

230-Hour Cyclic Conditions

10.4.1

Shutdown during 230-Hour Cyclic

10.4.2

Shutdown and Maintenance

10.5

Normal Shutdown

10.5.1

Emergency Shutdown

10.5.2

Maintenance

10.5.3

Downtime

10.5.4

Operating conditions

10.6

Stage Transition Times

10.6.1

Test Timer

10.6.2

Operational Data Acquisition

10.6.3

Operational Data Reporting

10.6.4

Coolant Sampling

10.6.5

Oil Sampling

10.6.6

End of Test (EOT)

10.7

Shutdown

10.7.1

Oil Drain

10.7.2

Coolant Drain

10.7.3

Engine Disassembly

10.7.4

Calculations, Ratings and Test Validity

11

Liner Pit Count

11.1

Coolant Analysis

11.2

Oil Analyses

11.3

Assessment of Operational Validity

11.4

Report

12

Report Forms

12.1

Reference Coolant Test

12.2

Electronic Transmission of Test Results

12.3

Precision and Bias

13

Precision

13.1

Intermediate Precision Conditions

13.1.1

Intermediate Precision Limit

13.1.2

Reproducibility Conditions

13.2

Reproducibility Limit

13.2.1

Bias

13.3

Keywords

14

Annexes

Safety Precautions

Annex A1

Intake Air Aftercooler

Annex A2

Engine Build Parts Kit

Annex A3

Sensor Locations, Special Hardware, and Engine Block
   Modifications

Annex A4

Fuel Specifications

Annex A5

John Deere Service Publications

Annex A6

Specified Units and Formats

Annex A7

Report Forms and Data Dictionary

Annex A8

Coolant Analysis

Annex A9

Oil Analysis

Annex A10

Determination of Operational Validity

Annex A11

Typical System Configurations

Appendix X1