ASTM D7583 Standard Test Method for John Deere Coolant Cavitation Test
6.1 Test Engine Configuration:
6.1.1 Test Engine - The John Deere 6101H is an inline six-cylinder heavy duty diesel engine with 10.1 L of displacement and is turbocharged and aftercooled. The engine has an overhead valve configuration. It features mechanical control of fuel metering and fuel injection timing.
6.1.2 Oil Pan Modification - Modify the oil pan as shown in Fig. A4.9.
6.2 Test Stand Configuration:
6.2.1 Engine Mounting - Install the engine so that it is upright and the crankshaft is horizontal.
18.104.22.168 The engine mounting hardware should be configured to minimize block distortion when the engine is fastened to the mounts. Excessive block distortion may influence test results.
6.2.2 Intake Air System - With the exception of the intake air tube, the intake air system is not specified. A typical configuration is shown in Fig. X1.1. The air filter should be typical of air filters used for engines in heavy-duty applications. Install the intake air tube (Fig. A4.2) near the intake of the turbocharger compressor. The system shall allow control of applicable parameters listed in Table 1.
6.2.3 Aftercooler - Use a Modine aftercooler. Instructions for obtaining the correct aftercooler are listed in A2.1.
NOTE 1 - Difficulty in achieving or maintaining intake manifold pressure or intake manifold temperature, or both, may be indicative of insufficient or excessive restriction.
6.2.4 Exhaust System - Install the exhaust tube (Fig. A4.7) near the discharge flange of the turbocharger turbine housing. The piping downstream of the exhaust tube is not specified. A method to control exhaust pressure is required.
6.2.5 Fuel System - The fuel supply and filtration system is not specified. A typical configuration is shown in Fig. X1.2. The fuel consumption rate is determined by measuring the rate of fuel flowing into the day tank. A method to control the fuel temperature is required.
6.2.6 Coolant System - The system configuration is not specified. Atypical configuration consists of a non-ferrous core heat exchanger, a reservoir (expansion tank), a temperature control valve, and a vent line from the coolant vent block on the engine to the bottom of the expansion tank as shown in Fig. X1.3. This is a non-pressurized system. The system should have a sight glass to detect air entrapment.
6.2.7 Oil System:
22.214.171.124 Oil Volume - Although the system volume is not specified, an excessively large volume may increase the time required for the engine fluid temperatures to attain specification. A system volume of 50.5 L or less, including the volume contained in the engine, has proven satisfactory.
126.96.36.199 Pressurized Oil Fill System - The oil fill system is not specified. A typical configuration includes an electric pump, a 50-L reservoir, and a transfer hose. The location for the pressurized fill is located on the filter head (Fig. A4.12).
188.8.131.52 External Oil System - Configure the external oil system according to Fig. A4.12. Use a 10 to 13 L container for the external oil reservoir. Use Viking Pump model number SG053514. Nominal pump motor speed is 1725 r/min.
184.108.40.206 Oil Sample Valve Location - Locate the oil sample valve on the return line from the external oil system to the engine. Locate the valve as close to the return pump as possible (Fig. A4.11).
220.127.116.11 Unacceptable Oil System Materials - Brass or copper fittings can influence used oil wear metals analyses and shall not be used in the external oil system.
6.3 Crankcase Aspiration - Vent the blowby gas at the port located on the left side of the valve cover (Fig. A4.10). Route the vent line downward from the valve cover port to the blowby canister. The line shall be between 1.2 and 1.8 m in length and minimum 15.9 mm inside diameter.
6.4 Blowby Rate - The flow rate measurement device is not specified. The blowby canister shall be a minimum of 35 L in volume. The outlet of the blowby canister to the flow rate device shall be a minimum of 31.8 mm inside diameter. The hose connecting the blowby canister to the flowrate device shall be a minimum of 38.1 mm inside diameter. The length of this hose is not specified.
6.5 System Time Responses - The maximum allowable system time responses are shown in Table 2.
6.6 Clearance Measurements - Piston skirt outside diameter and liner inside diameter, piston pin, rod and main bearings.
6.6.1 Piston Skirt - Measure and record the piston skirt outside diameter.
Spec = 130.04 - 130.05 mm, max
6.6.2 Main Bearings - Inspect the crankshaft main bearings for condition and clearance. The crankshaft will have to be supported to perform the plastigage clearance check.
Spec = 0.046 - 0.152 mm, max
6.6.3 Rod Bearings - Inspect the crankshaft main bearings for condition and clearance. The crankshaft will have to be supported to perform the plastigage clearance check.
Spec = 0.046 - 0.152 mm, max
6.6.4 Cylinder Liners - Measure and record the cylinder liners inside diameter.
OEM liner ID spec = 130.165 - 130.175 mm
Test liner ID spec = Piston Skirt OD + 0.254 mm
Test liner OD spec = Block ID - 0.1016 mm
6.6.5 Piston Ring End Gap - Measure and record the piston ring end gap and the oil control ring side clearance.
Spec Top = 0.432 - 0.686 mm
2nd = 1.016 - 1.27 mm
Oil = 0.330 - 0.635 mm
OCSC = 0.061 - 0.102 mm
New Max Used = 0.165 cm
6.6.6 Piston Pin to Connecting Rod Bushing - Measure and record the piston pin to connecting rod bushing clearance.
Spec = 0.018 - 0.762 mm
6.6.7 Connecting Rod Bearing Clearance - Install the pistons and connecting rods. Use plastigage to measure the connecting rod bearing clearance.
Spec = 0.051 - 0.127 mm
6.6.8 Cylinder Head - Measure and record the cylinder head specifications as per Table 3.
7. Engine and Cleaning Fluids
7.1 Engine Oil - Approximately 70 L of John Deere Plus 50 TY6391 is required to complete the test.
7.2 Test Fuel - Approximately 4500 gal of Off-Highway diesel fuel is required to complete the test. Fuel property tolerances are shown in Annex A5.
7.3 Engine Coolant - Use specified test coolant mixed with deionized water.
7.4 Solvent - Use a solvent which meets Specification D235 for mineral spirits, Type II, Class C for Aromatic Content (0 - 2 % vol), Flash Point (142° F / 61° C, min), and Color (not darker than +25 on Saybolt Scale or 25 on Pt-Co Scale). Obtain a Certificate of Analysis for each batch of solvent from the supplier. Warning - Combustible. Health Hazard. Use adequate safety precautions with all solvents and cleaners.