Cummins M11 Engine

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M11 EGR Preliminary Draft #4a
October 12, 2001
THIS DOCUMENT IS NOT AN ASTM STANDARD; IT IS UNDER CONSIDERATION WITHIN AN ASTM TECHNICAL COMMITTEE BUT HAS NOT
RECEIVED ALL APPROVALS REQUIRED TO BECOME AN ASTM STANDARD. IT SHALL NOT BE REPRODUCED OR CIRCULATED OR QUOTED, IN
WHOLE OR IN PART, OUTSIDE OF ASTM COMMITTEE ACTIVITIES EXCEPT WITH THE APPROVAL OF THE CHAIRMAN OF THE COMMITTEE
HAVING JURISDICTION AND THE PRESIDENT OF THE SOCIETY.
COPYRIGHT ASTM, 100 BARR HARBOR DRIVE, WEST CONSHOHOCKEN, PA 19428-2959 ALL RIGHTS RESERVED.

ASTM Designation: DXXXX – XX

Standard Test Method for

Evaluation of Diesel Engine Oils in the Cummins M11 Engine with Exhaust
Gas Recirculation 1

This standard is issued under the fixed designation DXXXX; 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 esilion
(ε) indicates an editorial change since the last reapproval.
Coolant System 6.2.7
Pressurized Oil Fill System 6.2.8
1. Scope External Oil System 6.2.9
Crankcase Aspiration 6.2.10
1.1 This test method is commonly referred to as Blowby Rate 6.2.11
the Cummins M11 Exhaust Gas Recirculation System Time Responses 6.3
Test (EGR)2. The test method defines a heavy- Oil Sample Containers
Mass Balance
6.4
6.5
duty diesel engine test procedure to evaluate oil Engine and Cleaning Fluids 7
performance with regard to valve train wear, Test Oil 7.1
Test Fuel 7.2
power cylinder wear, sludge deposits, and oil Engine Coolant 7.3
filter plugging3 in an EGR environment. Solvent 7.4
Preparation of Apparatus 8
1.2 The values stated in SI units are to be Cleaning of Parts 8.1
regarded as the standard. The values given in Crosshead Cleaning and Measurement 8.1.6
Rod Bearing Cleaning and Measurement 8.1.7
parenthesis are for information only. Ring Cleaning and Measurement 8.1.8
1.3 This standard does not purport to address all Injector Adjusting Screw Cleaning
of the safety concerns, if any associated with its and Measurement 8.1.9
Engine Assembly 8.2
use. It is the responsibility of the user of this General 8.2.1
standard to establish appropriate safety and Parts Reuse and Replacement 8.2.2
Build-Up Oil 8.2.3
health practices, and determine the applicability Coolant Thermostat 8.2.4
of regulatory limitations prior to use. See A1 for Oil Thermostat 8.2.5
Fuel Injectors 8.2.6
general safety precautions. New Parts 8.2.7
Operational Measurements 8.3
Units and Formats 8.3.1
1.4 Table of Contents: Instrumentation Calibration 8.3.2
Temperatures 8.3.3
Pressures 8.3.4
Scope 1 Flow Rate 8.3.5
Referenced Documents 2 Engine/Stand Calibration and Non-Reference Oil Tests 9
Terminology 3 General 9.1
Summary of Test Method 4 New Test Stand 9.2
Significance and Use 5 Stand Calibration Period 9.3
Apparatus 6 Stand Modification and Calibration Status 9.4
Test Engine Configuration 6.1 Test Numbering System 9.5
Test Engine 6.1.1 Reference Oil Test Acceptance 9.6
Oil Heat Exchanger, Adapter Blocks, Unacceptable Reference Oil Test 9.7
and Block Off Plate 6.1.2 Reference Oil Accountability 9.8
Oil Filter Head Modicfication 6.1.3 Non-Reference Oil Tests 9.9
Oil Pan Modification 6.1.4 Test Procedure 10
Engine Control Module 6.1.5 Engine Installation and Stand Connections 10.1
Engine Postion Sensor 6.1.6 Coolant System Fill 10.2
Air Compressor and Fuel Pump 6.1.7 Oil Fill for Break-in 10.3
Test Stand Configuration 6.2 Fuel Samples 10.4
Engine Mounting 6.2.1 Engine Warm-up 10.5
Intake Air System 6.2.2 Engine Break-in 10.6
Aftercooler 6.2.3 Shutdown and Maintenance 10.7
Exhaust System 6.2.4 300-h Test Procedure 10.8
Exhaust Gas Recirculation System 6.2.5 Oil Fill for Test 10.8.2
Fuel Supply 6.2.6 Zero-h Oil Sample 10.8.3.1

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 M11 EGR Preliminary Draft #4a
October 12, 2001
Operating Conditions 10.8.4 D 613 Standard Test Method for Cetane
Injection Timing Change 10.8.5
%Soot Validity 10.8.6 Number of Diesel Fuel Oil5
Test Timer 10.8.7 D 664 Standard Test Method for Acid Number
Operational Data Acquisition 10.8.8
Oil Purge, Sample and Addition 10.8.9 of Petroleum Products by Potentiometric
Full and Drain Weight 10.8.9.2 Titration4
End of Test (EOT) 10.9
Engine Disassembly 10.9.4
D 1319 Standard Test Method for Hydrocarbon
Calculations, Ratings and Test Validity 11 Types in Liquid Petroleum Products by
Crosshead Mass Loss
Injector Adjusting Screw Mass Loss
11.1
11.2
Fluorescent Indicator Absorption4
Rod Bearing Mass Loss 11.3 D 2500 Standard Test Method for Cloud Point
Sludge Ratings 11.4 of Petroleum Products4
Piston Ratings 11.5
Oil Filter Plugging 11.6 D 2622 Standard Test Method for Sulfur in
Oil Analyses 11.7 Petroleum Products by x-ray Spectrometry6
Oil Consumption 11.8
Fuel Analyses 11.9 D 2709 Standard Test Method for Water and
Ring Mass Loss 11.10 Sediment in Middle Distillate Fuels by
EGR % Mass and CO2 Probe Locations 11.11
Assessment of Operational Validity 11.12
Centrifuge6
Assessment of Test Interpretability 11.13 D 2896 Standard Test method for Base Number
Test Report 12 of Petroleum Products by Potentionmetric
Precision and Bias 13
Keywords 14 Perchloric Acid Titration6
Annexes D 4485 Specification for Performance of Engine
Safety Precautions Annex A1
Mandatory Supplier List Annex A2 Oils6
Engine Build Parts Kit Annex A3 D 6483 Standard Test Method for Evaluation of
Sensor Locations and Special Hardware Annex A4
External Oil System Annex A5 Diesel Engine Oils in T-9 Diesel Engine
Fuel Specification Annex A6 D 4737 Standard Test Method for Calculated
Cummins Service Publications
Specified Units and Formats
Annex A7
Annex A8
Cetane Index by Four Variable Equation7
Piston Rating Locations Annex A9 D4739 Standard Test method for Base Number
Oil Analyses Annex A10 Determination by Potentiometric Titration7
Oil Filter Plugging Annex A11
Determination of Operational Validity Annex A12 D 5185 Standard Test Method for Determination
of Additive Elements, Wear Metals, and
Appendixes
Non-Mandatory Suppliers List X1 Contaminants in Used Lubricating Oils and
Typical System configurations X2 Determination of Selected Elements in Base Oils
by Inductively Coupled Plasma Atomic Emission
2. Referenced Documents Spectrometry (ICP-AES)7
D 5302 Test Method for Evaluation of
2.1 ASTM Standards: Automotive Engine Oils for Inhibition of Deposit
D 86 Standard Test Method for Distillation of Formation and Wear in a Spark-Ignition Internal
Petroleum Products4 Combustion Engine Fueled with Gasoline and
D 92 Standard Test Method for Flash and Fire Operated Under Low-Temperature, Light Duty
Points by Cleveland Open Cup4 Conditions7
D 97 Standard Test Method for Pour Point of D 5844 Standard Test Method for Evaluation of
Petroleum Products4 Automotive Engine Oils for Inhibition of Rusting
D 129 Standard Test Method for Sulfur in (Sequence IID)7
Petroleum Products4 D 5967 Standard Test Method for Evaluation of
D 130 Standard Test Method for Detection of Diesel Engine Oils in T-8 Diesel Engine7
Copper Corrosion from Petroleum Products by E 29 Practice for Using Significant Digits in Test
the Copper Strip Tarnish Test4 Data to Determine Conformance with
D 287 Standard Test Method for API Gravity of Specifications8
Crude Petroleum and Petroleum Products E178 Standard Practice for Dealing with
(Hydrometer Method)4 Outlying Observations
D 445 Standard Test Method for Kinematic E 344 Terminology Relating to Thermometry in
Viscosity of Transparent and Opaque Liquids Hydromometry9
(and the Calculation of Dynamic Viscosity)4 2.2 Coordinating Research Council:
D 482 Standard Test Method for Ash from CRC Manual No. 1210
Petroleum Products4 CRC Manual No. 18 (Revised May, 1994)10
D 524 Standard Test Method for Ramsbottom
Carbon Residue of Petroleum Products4 3. Terminology

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 M11 EGR Preliminary Draft #4a
October 12, 2001
3.1 Definitions: arm travel to the opening and closing of each
3.1.1 blind reference oil, n - a reference oil, the valve pair.
identity of which is unknown by the test facility. 3.2.1.1 Discussion -- Each cylinder has two
D 5844 crossheads, one for each pair of intake valves and
3.1.1.1 Discussion – This is a coded reference exhaust valves.
oil that is submitted by a source independent of 3.2.2 exhaust gas recirculation (EGR), n - a
the test facility. method by which a portion of engine’s exhaust is
3.1.2 blowby, n  in internal combustion returned to its combustion chambers via its inlet
engines, the combustion products and unburned system.
air-and-fuel mixture that enter the crankcase. 3.2.3 overhead, n – in internal combustion
D 5302 engines, the components of the valve train
3.1.3 calibrate, v - to determine the indication or located in or above the cylinder head.
output of a measuring device with respect to that 3.2.4 overfuel, v – an operating condition in
of a standard. E 344 which the fuel flow exceeds the standard
3.1.4 heavy-duty, adj – in internal combustion production setting.
engine operation, characterized by average 3.2.5 valve train, n – in internal combustion
speeds, power output, and internal temperatures engines, the series of components such as valves,
that are close to the potential maximum. crossheads, rocker arms, push rods and camshaft,
D 4485 which open and close the intake and exhaust
3.1.5 heavy-duty engine, adj – in internal valves.
combustion engines, one that is designed to allow 4. Summary of Test Method
operation continuously at or close to its peak 4.1 This test method uses a Cummins M11 400
output. D 4485 diesel engine, with a specially modified engine
3.1.6 non-reference oil, n  any oil other than a block. Test operation includes a 25-min. warm-
reference oil, such as a research formulation, up, a 2-h break-in, and 300 h in six 50-h stages.
commercial oil or candidate oil. D 5844 During stages A, C and E, the engine is operated
3.1.7 non-standard test, n – a test that is not with retarded fuel injection timing and is
conducted in conformance with the requirements overfueled to generate excess soot. During
in the standard test method; such as running in an stages B, D and F, the engine is operated at
non-calibrated test stand or using different test conditions to induce valve train wear.
equipment, applying different equipment 4.2 Prior to each test, the engine is cleaned and
assembly procedures, or using modified assembled with new cylinder liners, pistons,
operating conditions. D 5844 piston rings and overhead valve train
3.1.8 reference oil, n – an oil of known components. All aspects of the assembly are
performance characteristics, used as a basis for specified.
comparison. D 4485 4.3 A forced oil drain, an oil sample and an oil
3.1.9 sludge, n  in internal combustion addition, equivalent to an oil consumption of 0.23
engines, a deposit, principally composed of g/kW-h, is performed at the end of each 25-h
insoluble resins and oxidation products from fuel period.
combustion and the lubricant, that does not drain 4.4 The test stand is equipped with the
from engine parts but can be removed by wiping appropriate instrumentation to control engine
with a cloth. D 5302 speed, fuel flow, and other operating parameters.
3.1.10 wear, n  the loss of material from, or 4.5 Oil performance is determined by
relocation of material on, a surface. D 5302 assessing crosshead wear at 8.5% soot, top ring
3.1.10.1 Discussion – Wear generally occurs wear, sludge deposits and oil filter plugging.
between two surfaces moving relative to each 5. Significance and Use
other, and is the result of mechanical or chemical 5.1 This test method was developed to assess
action or by a combination of mechanical and the performance of a heavy-duty engine oil to
chemical actions. control engine wear and deposits under operating
3.2 Descriptions of Terms Specific to This conditions selected to accelerate soot production,
Standard: valve train wear, and deposit formation in a turbo-
3.2.1 crosshead, n  an overhead component, charged and intercooled four-cycle diesel engine
located between the rocker arm and each intake equipped with exhaust gas recirculation hardware.
valve and exhaust valve pair, that transfers rocker 5.2 The design of the engine used in this test
method is representative of many, but not all,

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 M11 EGR Preliminary Draft #4a
October 12, 2001
modern diesel engines. This factor, along with 6.2.1 Engine Mounting — Install the engine so
the accelerated operating conditions shall be that it is upright and the crankshaft is horizontal.
considered when extrapolating test results. 6.2.1.1 Discussion - The engine mounting hard-
6. Apparatus ware should be configured to minimize block
6.1 Test Engine Configuration: distortion when the engine is fastened to the
6.1.1 Test Engine -- The Cummins M11 400 is an mounts. Excessive block distortion can influence
in-line six-cylinder heavy-duty diesel engine with test results.
11 L of displacement and is turbocharged, 6.2.2 Intake Air System– With the exception of
aftercooled, has an overhead valve configuration the air filter and the intake air tube, the intake air
and EGR hardware. It features a 1994 emissions system is not specified. A typical configuration is
configuration with electronic control of fuel shown in Fig. X2.1. The air filter shall have a
metering and fuel injection timing. Obtain the minimum initial efficiency rating of 99.2%. Install
test engine and the engine build parts kit from the the intake air tube (Fig A4.5) at the intake of the
supplier listed in A2.2. The components of the turbocharger compressor. Construct the system to
engine build parts kit are shown in Table A3.1. minimize airflow restriction. To control intake
6.1.2 Oil Heat Exchanger, Adapter Blocks, and manifold pressure a restriction plate or valve may
Block-off Plate — The oil heat exchanger is be used after the aftercooler and before the inlet air
relocated from the stock position with the use of tubing. A method to cool the intake air is required.
adapter blocks as shown in Fig. A4.1. Install an 6.2.2.1 Discussion - Difficulty in achieving or
oil cooler block-off plate on the back of the maintaining intake manifold pressure or intake
coolant thermostat housing as shown in Fig. A4.1. manifold temperature, or both, could be indicative
The adapter blocks can be obtained from the of insufficient or excessive restriction.
supplier listed in X1.3. Control the oil 6.2.3 Aftercooler – A Modine aftercooler, P/N
temperature by directing engine coolant through 1A012865, will be used for aftercooling. The
the oil heat exchanger (Fig A4.2). aftercoolers can be obtained from the supplier
6.1.3 Oil Filter Head Modification – Modify the listed in X.1.5.
oil filter head by plugging the filter bypass return 6.2.4 Exhaust System – Install the exhaust tube
to sump line and the engine oil thermostat (Fig (Fig A4.6) at the discharge flange of the
A4.8). The thermostat passage should blocked to turbocharger turbine housing. The piping
route all of the engine oil into the oil cooler. downstream of the exhaust tube is not specified. A
6.1.4 Oil Pan Modification — Modify the oil pan method to control exhaust pressure is required.
as shown in Fig. A4.3. A modified oil pan can be 6.2.5 Exhaust Gas Recirculation System -- The
obtained from the supplier listed in X1.3. set-up components for the exhaust gas
6.1.5 Engine Control Module (ECM) — Obtain recirculation system (Fig A4.10) can be obtained
the ECM from the supplier listed in A2.2. The from the supplier listed in X.1.2.
ECM programming has been modified to provide 6.2.6 Fuel Supply – The fuel supply and filtration
overfueling and retarded injection timing to system is not specified. A typical configuration is
increase soot generation and overhead wear. The shown in Fig. X2.2. The fuel consumption rate is
de-rate protocols have been disabled, however determined by measuring the rate of fuel flowing
the de-rate messages will still be displayed when into the day tank. A method to control the fuel
using Cummins electronic service tools. temperature is required.
6.1.6 Engine Position Sensor – The engine 6.2.7 Coolant System – The system config-
position sensor has two measurement coils. The uration is not specified. A typical configuration
secondary coil must be disabled by cutting the consists of a non-ferrous core heat exchanger, a
two external, outside wires colored red and reservoir (expansion tank) and a temperature
black. The wires are also labeled A and D on the control valve as shown in Fig. X2.3. Pressurize
engine position sensor plug. (Fig A4.15) the system by regulating air pressure at the top of
6.1.7 Air Compressor and Fuel Pump -- The the expansion tank. The system should have a
engine-mounted air compressor is not used for this sight glass to detect air entrapment.
test method. Remove the air compressor and 6.2.7.1 Discussion - Although the system volume
install the fuel injection pump in its place (Fig. is not specified, an excessively large volume can
A4.4). The fuel injection pump is driven with increase the time required for the engine fluid
Cummins coupling P/N 208755. The coupling can temperatures to attain specification. A system
be obtained from the supplier listed in X1.1. volume of 45 L or less (including engine) has
6.2 Test Stand Configuration: proven satisfactory.

4
Cummins M11 Engine
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M11 EGR Preliminary Draft #4a
October 12, 2001
6.2.8 Pressurized Oil Fill System – The oil fill 7.3 Engine Coolant – Use pre-mixed
system is not specified. A typical configuration Fleetguard Compleat PG. The coolant can be
includes an electric pump, a 50-L reservoir, and obtained from the supplier listed in X1.1.
transfer hose. The location for pressurized fill is 7.4 Solvent – Aliphatic naphtha or equivalent.
located on the filter head (Fig A4.8) 7.4.1 Discussion – Use adequate safety pre-
6.2.9 External Oil System — Configure the ex- cautions with all solvents and cleaners.
ternal oil system according to Fig. A5.1. The 8. Preparation of Apparatus
external reservoir shall be Moroso P/N 22660, 8.1 Cleaning of Parts:
which can be obtained from the supplier listed in 8.1.1 General – The preparation of test engine
X1.4. components specific to the Cummins M11 EGR
6.2.9.1 Oil Sample Valve Location - The oil test are indicated in this section. Use the
sample valve shall be located on the return line Cummins service publications13 listed in A7 for
from the external oil system to the engine. It is the preparation of other engine components.
recommended that the valve be located as close Take precautions to prevent rusting of iron
to the return pump as possible (Fig. A5.1). components.
6.2.9.1.1 Discussion - Brass or copper fittings can 8.1.2 Engine Block – Disassemble the engine -
influence used oil wear metals analyses and shall including removal of the crankshaft, camshaft,
not be used in the external oil system. piston cooling tubes, oil pump, oil gallery plugs –
6.2.10Crankcase Aspiration – Vent the blowby and thoroughly clean the surfaces and oil passages
gas at the port located on the left side of the valve (galleries). It is recommended that the oil
cover. The vent line shall proceed downward from passages be cleaned with a brush. Removal of
the valve cover port to the blowby canister and be camshaft bearings is at the discretion of the
of a length between 1.2 and 1.8 meters and of a laboratory.
diameter of 1.588 cm. 8.1.3 Cylinder Head – Disassemble and clean the
6.2.11 Blowby Rate — The flowrate device cylinder head. Use a brush as necessary to remove
is not specified. The blowby canister shall be deposits.
37.88 L in volume. The outlet of the blowby 8.1.4 Rocker Cover and Oil Pan – Clean the
canister to the flowrate device shall be 3.18 cm in rocker cover and oil pan. Use a brush as necessary
diameter. The hose connecting the blowby to remove deposits.
canister to the flowrate device shall be 3.81 cm in 8.1.5 External Oil System -- Flush the internal
diameter the length of which is not specified. surfaces of the oil lines and the external reservoir
6.3 System Time Responses – The maximum with solvent. Repeat until the solvent drains clean.
allowable system time responses are shown in Flush solvent through the oil pumps until the
Table 1. Determine system time responses in solvent drains clean.
accordance with the Data Acquisition and Control 8.1.6 Crosshead Cleaning and Measurement
Automation II (DACA II) Task Force Report12. 8.1.6.1 Handling and Orientation - Avoid
6.4 Oil Sample Containers — High-density handling the crossheads with bare hands, use
polyethylene containers are recommended for oil gloves or plastic covered tongs. Crossheads shall
samples. be oriented in the engine with the elongated slot
6.4.1 Discussion — Glass containers may break to the exhaust valve.
and may cause injury or exposure to hazardous 8.1.6.2 Clean the crossheads with solvent. Use a
materials, or both. non-metallic soft bristle brush if necessary.
6.5 Mass Balance — A balance is required to 8.1.6.3 Spray the crossheads with air until dry.
measure the mass of the crossheads and rod 8.1.6.4 Rinse the crossheads in pentane and dry
bearings. An electronic or mechanical balance with air.
may be utilized. The balance shall have a 8.1.6.5 Measure crosshead mass to a tenth of a
minimum indication resolution of 0.1 mg. milligram (xxx.x mg).
7. Engine and Cleaning Fluids 8.1.6.6 If an electronic scale is used for mass
7.1 Test Oil -- Approximately 115 L of test oil measurement, then use the following procedure:
is required to complete the test. (a) Demagnetize (degauss) each crosshead prior
7.2 Test Fuel -- Approximately 20,000 L of to measurement
diesel fuel is required to complete the test. (b) Measure the crosshead twice, using two
Purchase the fuel from the supplier listed in orientations 90° apart. If the difference between
A2.1. The fuel shall have the properties and the two mass measurements is greater than 0.2 mg,
tolerances shown in A6. the crosshead shall be demagnetized and the

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