Significance and Use
5.1 This test method was developed to evaluate the ability of a heavy-duty diesel engine coolant to provide protection against damage resulting from a phenomenon known as cylinder liner cavitation corrosion.
5.2 This test method may be used for engine coolant specification acceptance when all details of this test method are in compliance.
5.3 The design of the engine used in this test method is a production OEM diesel engine modified to consistently produce the operating conditions that accelerate damage from cylinder liner cavitation. This factor, along with the accelerated operating conditions needs to be considered when extrapolating test results.
Scope
1.1 This test method is commonly referred to as the John Deere Cavitation Test.2 The test method defines a heavy-duty diesel engine to evaluate coolant protection as related to cylinder liner pitting caused by cavitation.
1.2 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only. The only exception is where there is no direct SI equivalent such as screw threads, national pipe threads/diameters, and tubing sizes.
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. See Annex A1 for general safety precautions.
1.4 Table of Contents:
| 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 | 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 | 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 |
