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.
Область применения1.1 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
Tests
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
Modifications
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