ASTM D7583 Standard Test Method for John Deere Coolant Cavitation Test
10. Procedure
10.1 Engine Installation and Stand Connections - Install the test engine on the stand and connect the engine to the stand support equipment.
NOTE 2 - A final check of valve and injector settings is recommended at this time.
10.2 Break-in - Perform a break-in on each new engine build prior to the start of the 250-h test procedure.
10.2.1 Coolant System Fill for Break-in:
10.2.1.1 Install a new Deere RE1192 coolant filter.
10.2.1.2 Charge the cooling system with 52 L of the specified concentration of new coolant and record the weight.
10.2.1.3 Coolant Sample - Take a 0.5 L coolant sample at the start of the break-in.
NOTE 3 - The coolant system should be pressurized to specification and checked for leaks prior to adding the engine oil.
10.2.2 Oil Fill for Break-in:
10.2.2.1 Install a new Deere RE44647 oil filter.
10.2.2.2 Use the pressurized oil fill system (6.2.7.2) to charge the engine with 33.7 L of John Deere Torque Guard Plus 50 oil at the location shown in Fig. A4.12.
10.2.2.3 Oil Sample - Take a 0.25 liter oil sample at the start of the break-in.
10.2.3 Engine Build Committed - After the test coolant has been introduced into the engine, the engine build and the test number are valid only for the respective test. However, if the engine has not been started (whereby the test parts have not been subjected to heated coolant), then the new build may be used again.
10.2.4 Break-in Conditions - Start the engine and proceed directly to the break-in (Table 4).
10.2.5 Shutdown during Break-in - If a shutdown occurs during the break-in, rerun the entire break-in.
10.2.6 At the completion of the break-in, perform a normal shutdown (Table 5) and shut off the engine.
10.2.7 Drain the oil from the engine and the external oil system.
10.2.8 Remove the RE44647 oil filter.
10.2.9 Properly dispose of the drain oil and oil filter.
10.2.10 Once completed, the break-in is not repeated for the respective test.
NOTE 4 - Use the break-in as an opportunity to confirm engine performance and to make repairs prior to the start of the 250-h test procedure.
10.3 250-Hour Test Procedure:
10.3.1 Coolant Fill for Test - Charge the system with approximately 52 L of the specified concentration of new coolant and record the weight.
10.3.1.1 Zero-hour Coolant Sample - Take a 0.7 L coolant sample of the fresh coolant from the original container.
10.3.2 Oil Fill for Test - Use the pressurized oil fill system (6.2.7.2) to charge the engine with 33.7 kg of John Deere Plus 50 oil at the location shown in Fig. A4.12.
10.3.2.1 Zero-hour Oil Sample - Take a 0.4 L oil sample of the fresh oil from the original oil container.
10.3.3 Warm Up - This warm-up procedure is used after the break-in and every time the engine is brought up.
10.3.3.1 Start the engine and perform the warm-up (Table 6).
10.3.3.2 Shutdown During Warm-up - If a shutdown occurs during the warm-up restart the warm-up procedure.
10.3.4 20-Hour Steady State Extended Break-in - After the warm-up, proceed directly to the 20-h Steady State Extended Break-in (Table 7).
10.3.4.1 Run the engine at the conditions stated in the 20-Hour Steady State Extended Break-in Conditions (Table 7).
10.3.4.2 Shutdown During Extended Break-in - If a shut-down occurs during the 20-Hour Extended Break-in, Stop the Test Timer and proceed to the Normal Shutdown (Table 5).
10.4 230-Hour Cyclic - No intervention is necessary between the 20-Hour Steady State and the 230-Hour Cyclic portions of the test.
10.4.1 Run the engine at the conditions stated in the 230-Hour Test Sequence (Table 1).
10.4.2 Shutdown During 230-Hour Cyclic - If a shutdown occurs during the 230-Hour Cyclic, Stop the Test Timer and proceed to the Normal Shutdown (Table 5).
10.5 Shutdown and Maintenance - The test may be shut down at the discretion of the laboratory to perform repairs. However, the intent of this test method is to conduct the 250-h test procedure without shutdowns.
10.5.1 Normal Shutdown - Proceed directly from the operating conditions to the shutdown schedule (Table 5).
10.5.2 Emergency Shutdown - An emergency shutdown occurs when the normal shutdown cannot be performed, such as an alarm condition.
10.5.3 Maintenance - Engine components or stand support equipment, or both, may be repaired or replaced at the discretion of the laboratory and in accordance with this test method.
10.5.4 Downtime - The limit for total downtime and number of shutdowns is not specified. Record all shutdowns, pertinent actions, and total downtime during the 250-h test procedure.
10.6 Operating Conditions:
10.6.1 Stage Transition Times - Less than 10 s with the exception of Intake Manifold Temperature.
10.6.2 Test Timer - The 250-h test timer starts when all controlled parameters in the Steady State Extended Break-in are within specification. If a shutdown occurs, stop the test timer immediately at the initiation of the shutdown. The test timer shall resume when the test has been returned to the appropriate stage and all controlled parameters are within specification.
10.6.3 Operational Data Acquisition - Record all operational parameters shown in Tables 1 and 7, with automated data acquisition 15 s before the end of each step.
10.6.4 Operational Data Reporting - The operational data is reported on Form 5 listed in Annex A8, Table A8.1.
10.6.5 Coolant Sampling - Take a coolant sample at the end of each 125-h period. Do not shut down the engine for coolant sampling.
10.6.5.1 Coolant Sample - Remove a nominal 500-mL coolant sample and retain at the stand. Identify the coolant sample container with the test number, coolant code, date, and test hour.
10.6.6 Oil Sampling - Take an oil sample at the end of each 50-h period before any new oil is added during the oil addition procedure. Do not shut down the engine for oil sampling and oil addition.
10.6.6.1 Oil Sample - Remove a nominal 250-mL purge. Remove a nominal 250-mL oil sample and retain at the stand. Return the purge to the engine oil system. Identify the oil sample container with the test number, date, and test hour.
10.6.6.2 Oil Addition - Verify oil adder tank is approximately 50 % full after 1 h. After the oil sampling has been completed at the end of each 50-h period, add John Deere Plus 50 as needed to return to the full mark.
10.7 End of Test (EOT):
10.7.1 Shutdown - After completing the test procedure, perform a normal shutdown (Table 5), and shut down the engine. Disconnect the test stand support equipment. Warning - The coolant and oil may be hot. The installation of a valve to safely vent the coolant system pressure is recommended.
10.7.2 Oil Drain - Drain the oil from the engine and the external oil system and retain at stand.
10.7.3 Coolant Drain - Drain the coolant from the engine and external cooling system and retain at stand.
10.7.4 Engine Disassembly - Disassemble the engine and remove the liners for ratings.
11. Calculations, Ratings and Test Validity
11.1 Liner Pit Count - Using a microscope, place the transparent grid (squares are 2.14 mm) on the liner surface over the pitted area(s) of the liner. Assign a count of one pit area to each grid square containing a pit or pits. The pit (or pits) does not have to cover the entire square. If any portion of a pit or group of pits is contained in a square, it receives a count of one. Total all the pit areas on a given liner. Total the pit areas on all six liners, and this is the total pit count for the coolant being tested.
11.2 Coolant Analysis - Typical coolant analysis results are itemized in Annex A9.
11.3 Oil Analysis - Typical oil analysis results are listed in Annex A10.
11.4 Assessment of Operational Validity - Determine operational validity according to Annex A11.
