250-HOUR HIGH-SPEED DURABILITY TESTING INSTRUCTIONS
EVERY 50 EVERY 50 HOURS
Stop the engine. Position to No. 1 top dead center (TDC), and wait 5 minutes for the oil to drain down.
Take 50 ml of lube oil sample from the sump, and label the sample jar with the dynamometer cell number, the engine number, the test
hours, and the date. Record the weight of the oil sample (Wl).
Dip the oil, and add oil as necessary to restore the level t o the full dipstick mark.
Recheck the level after 5 minutes. Top up as required.
Record the weight of all oil added (W2).
Record the oil consumption, whereby Wc = W2 - W1.
Check/top up coolant as required. Record the volume added.
Review the engine performance using readings from full power stages.
Stop the test and inform the engineer i f the power drops by more than 10% from the highest previous stabilized readings.
Enqine Tests Used Within the Automotive Testinq lndsutry 9 1
Wipe down the engine, and record the nature, position, and magnitude of all leaks.
Visually inspect the crankshaft damper for signs of cracks in the rubber.
Conduct a blow-by test at the minimum load idle and the full load rated speed. Record the blow-by on the data sheet.
Check that the coolant flow is within limits, as specified on the Engine Test Request.
Drain the sump and fill it with a new test oil, as specified on the test request prior to draining. Top up as required to level, and record consumption.
Remove the oil filter, bag it, and label with the test detail. Fit a new filter.
Check/adjust the valve clearances. Record the results on the valve clearance data sheet.
Perform a daily dyno calibration check.
Process the logged data. Report any deviation from the test specification to the Requesting Engineer.
END OF TEST SCHEDULE AT 2 5 0 HOURS
Stop the engine. Position to No. 1 top dead center (TDC), and wait 5 minutes for the oil to drain down.
Take 50 ml of lube oil sample from the sump, and label the sample jar with the dynamometer cell number, the engine number, the test hours, and the date. Record the weight of the oil sample (W1).
Dip the oil, and add oil as necessary to restore the level to the full dipstick mark.
Recheck the level after 5 minutes. Top up as required.
Record the weight of all oil added (W2).
Record the oil consumption, whereby Wc = W2 - W1.
Check/top up coolant as required. Record the volume added.
Wipe down the engine, and record the nature, position, and magnitude of all leaks.
Visually inspect the crankshaft damper for signs of cracks in the rubber.
Examine the primary and auxiliary belts, and record the average hot and cold Clavis gauge tensions.
TAPPET CHECK
8.1 1.1 Check and record that the (cold) valve clearances are w i t h i n tolerance.
9 2 An Introduction t o Engine Testing and Development
8.1 1.2 Tappets must be reset before any of the final checks are completed.
8.1 2 FULL LOAD POWER CURVE
8.1 2.1 Perform a daily dyno calibration check.
8.1 2.2 Fit the instrumented injector to the cylinder No. 1 and the cylinder pressure transducer i f applicable.
8.1 2.3 Run a full-load power curve at speeds as applicable for the engine type. Record the parameters.
8.1 2.4 Process the power curve data. If the performance is significantly out of specification (refer to the Test Request), inform the Requesting Engineer.
8.1 3 HOT COMPRESSION AND INJECTOR FUNCTION CHECKS
8.1 3.1 Perform a hot compression check. Record the compression pressures, the coolant outlet temperatures, and the cranking speed (cranking speed minimum 180 rev/min).
8.1 3.2 Functionally check the injectors, and record as-found nozzle opening pressure (NOP). Refit the injectors with new injector washers and seals.
8.1 3.3 Remove the instrumented injector and cylinder pressure transducer (if applicable) and refit the originals.
8.14 GOVERNOR HYSTERESIS TEST
8.1 4.1 Run a governor run-out curve (if applicable to the FIP type).
8.1 4.2 Process the governor hysteresis data.
8.1 5 CRANKSHAFT TORSIONAL VIBRATION TEST
8.1 5.1 Inspect the crankshaft torsional damper for signs of cracking in the rubber.
8.1 5.2 Conduct a torsional vibration test.
8.1 5.3 Process the data, and produce plots.
8.16 OIL PRESSURE CURVE
8.16.1 Run an oil pressure curve at speeds applicable to the engine type.
Maintain a bulk oil temperature of 1 1 0°C.
8.1 6.2 Process the oil pressure curve data.
8.1 7 CRANKCASE BLOW-BY TEST
8.1 7.1 Record the crankcase blow-by at the following speeds. Stop the engine, and advise the Requesting Engineer if the levels are above the maximum listed in the Engine Test Request.
8.1 8 OIL CONSUMPTION TEST
8.1 8.1 Run a three-hour oil consumption test at the rated power
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8.1 9 NITROGEN PRESSURE TEST
8.1 9.1 Note and record the valve clearances. Do not reset.
8.1 9.2 Check and record the cold primary belt tensions.
8.1 9.3 Undertake a cylinder head gasket nitrogen pressure test.
8.1 9.4 A nitrogen pressure test must be conducted after the completion of all engine running.
8.20 FINAL CHECKS
Take a one-liter oil sample.
Remove the oil filter, bag it, and label with the test detail. Fit a new
filter. C
Remove the air filter, bag it, and label with the test detail.
Check the fuel filter for leakage. Remove, bag, and label it with the test details (if the vehicle filter has been fitted for the duration of the test).
Remove the power take-off unit, and perform a rear crankshaft oil seal leak examination.
Examine the whole engine, including under the timing belt cover, for leaks and a'ny signs of failure. Record the findings.
Remove any special test bed fittings. Replace the original parts low- pressure fuel pipes and hardware, vehicle thermostat, and coolant sender (if fitted).
Process the Engine Build and Test Record sheets and file them with the Engine Log Sheet and daily dyno calibration in the Supplementary Log. Do not dismount the engine until all end-of-test data have been reviewed by the Requesting Engineer.
Remove the engine from the test bed. Ensure that all components removed prior to the start of testing either are refitted to the engine or are labeled and returned with the engine.
Ensure that test oil samples and filters are returned with the engine.
Ensure that all failed components have a concern note raised against them.
Note that the order of completion of the final checks is discretionary. However, the valve clearance must be checked/adjusted before any of the performance tasks are completed, and the nitrogen pressure test must be conducted after all engine running is complete.
GENERAL NOTE
Prior to removing the engine from the test bed, please affix the labels.
Highlight any gas or liquid leaks noted, and any possible problem areas noted in the course of this test.
94 An Introduction t o Engine Testing and Development