X Approved For Supplier Distribution Internal To Deere Only: Worldwide Construction and Forestry Division Specification
X Approved For Supplier Distribution Internal To Deere Only: Worldwide Construction and Forestry Division Specification
X Approved For Supplier Distribution Internal To Deere Only: Worldwide Construction and Forestry Division Specification
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
Table of Contents
1. Scope 4
2. Supplier Capability Requirements 4
3. Definition of Terms 7
4. Design Rationale 8
5. Identification 9
6. Fluids 10
7. Test Documentation 12
8. Application Data 12
9. Fill Rate, De-aeration, and Draw-down 34
10. Vehicle composite for Thermal and Pressure Cycle Fatigue Life Calculations 34
11. Thermal Cycle Test 35
12. Pressure Drop Test (internal fluid) 39
13. Burst Test 40
14. Pressure Cycle Tests 42
15. Shock/ Vibration Tests 46
16. External Corrosion 47
17. Internal Erosion Corrosion for Radiators 48
18. Cleaning Requirements for External Fouling 48
19. In Vehicle Customer Reparability Requirements 48
20. End of Line (EOL) 48
21. Cleanliness Requirements 49
22. Manufacturing Quality Requirements 50
23. Allowable Heat Exchanger Aesthetics 50
24. Handling Protection 51
25. References 51
26. Appendix A: Reference material on erosion/corrosion 54
27. Appendix B Performance Characteristics 54
Table of Figures
Figure 1 Cooling System Layout 744/824L ....................................................................... 17
Figure 2 Envelop Dimensions ........................................................................................... 17
1. Scope
This document outlines:
1.1. The minimum capability that C&F suppliers are expected to meet for Cooling System
Heat Exchangers from the perspective of:
Engineering verification
Product verification & validation (PV&V)
End-of-line (EOL) leak test
1.2. Engineering design specifications
1.3. Performance requirements and characteristics
1.3.1. The supplier shall have the capability to measure performance
characteristics. Performance characteristics include heat transfer, internal
pressure drop and external pressure drop.
1.4. Durability requirements
1.4.1. The supplier and Deere shall collaborate to determine if durability
requirements are met. Durability requirements include pressure, thermal,
vibration and corrosion.
Volumetric airflow 5%
Percentages are of maximum reading. Precautions shall be taken to obtain readings
unaffected by turbulence and velocity.
2.2. The fluid for testing is that which is to be used in the C&F application. Contingent upon
approval from C&F, an alternate fluid can be used. Take into consideration global
applications wherein some factory fill methodologies, operator manuals, and regional
customs may predicate use of 80/20 water/coolant mix as this has been shown to
accelerate early hour internal corrosion due to reaction with potassium fluoroaluminate
(flux) overspray on internal components from the manufacturing processes deployed.
See section 16.
2.3. The supplier shall provide Deere with cooler performance information for use in cooling
system analysis. When appropriate, the supplier to provide cooling system
performance analysis. The preferred cooling analysis software is KULI.
2.4. A means to predict component durability will be required. Life predictions can use
either stress life or strain life predictions. Life shall be predicted individually with inputs
of pressure and thermal gradients. Information will be electronically shared with C&F.
2.5. Material selection
2.5.1. Heat exchanger materials and manufacturing process shall be compatible
with C&F fluids and systems.
2.6. Product Verification & Validation (PV&V)
2.6.1. At a minimum, production verification will be required on production tooled
parts. Depending on the nature of the design, design verification may also be
required. C&F will make the decision of whether or not design verification will
be required.
2.6.2. The supplier shall have the capability to perform testing or contract a test
facility to perform verification testing. At a minimum Deere shall be informed if
contract testing will occur. In some cases, Deere will participate in
communications with the contracted test facility.
2.6.3. Testing to be carried out until failure, with multiple samples and multiple
loading conditions so that a load life curve can be developed or strain life K f
factors can be determined.
2.6.4. All test failures must be reported to C&F immediately. For each failure,
analysis must be performed to determine failure mode and whether or not
failure is a result of the design or manufacturing. Corrective action
recommendations must also be submitted.
2.6.5. Pressure Drop Test
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 5 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
2.6.5.1. Supplier shall provide pressure drop vs. flow curves for
both the internal and external flows. C&F to define the fluid
flows and operating temperatures.
2.6.6. Heat Transfer Performance
2.6.6.1. Supplier shall provide heat transfer at four internal and four
external fluid flows. C&F to define the fluid flows.
2.6.7. Pressure Fatigue Test
2.6.7.1. Supplier shall perform pressure cycle testing to failure on
multiple samples and multiple loading conditions until failure.
C&F to define test parameters.
2.6.8. Thermal Cycle Test
2.6.8.1. Supplier shall have the capability to thermally cycle the
heat exchanger until failure. It is acceptable for supplier to use
a third party testing facility.
2.6.8.1.1. Supplier to provide guidance on strain gage locations.
Deere will install the strain gages.
2.6.8.1.2. Supplier to have ability to collected thermal strain data.
It is acceptable for supplier to use a third party testing
facility.
2.6.8.2. C&F will define a strain profile using a strain gaged heat
exchanger. Data will be collected using actual machine
operations. C&F then will provide the strain gauged heat
exchange and strain profile to the supplier to define the test
parameters.
2.6.9. External Corrosion
2.6.9.1. Supplier shall perform corrosion testing
2.6.10. Cleanliness
2.6.10.1. The supplier shall have capability to measure cleanliness.
C&F will provide the cleanliness requirements for each type of
heat exchanger.
2.6.11. Material and Manufacturing Compatibility with C&F Fluids
2.6.11.1. C&F to specify material and manufacturing compatibility
testing.
2.6.12. End of Line (EOL) Functional Test
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 6 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
3. Definition of Terms
3.1. ADV: Accelerated Design Verification. Test is designed to simulate a large number of
field hours in a relatively short amount of time
3.2. Air-to-Redline (ATR)
ATR is the primary performance measurement used by John Deere to determine
the in-vehicle cooling capacity of the radiator and all other heat exchanges
except condensers and CAC’s. It is defined by the following equation:
ATR = Tmax – Tmeas + Tamb
Where
Tmax = maximum allowable operating temperature (this could be
the top tank of radiator, an oil cooler inlet or an oil sump)
Tmeas = measured stabilized temperature during the prescribed
vehicle cooling performance test
Tamb = ambient air temperature during the prescribed vehicle
cooling performance test measured at a point reasonably
close to the vehicle, but not so close as to be influenced
by the vehicle.
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 7 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
4. Design Rationale
4.1. Design Objective Statement and System Concept
The cooling system design should focus on selecting the most cost effective
cooling system; where cost effective implies a cooling system providing
competitive performance while meeting customer expectations at a minimum
total cost over the life of the product. The models included in this DTW are
744L & 824L. One cooling package assembly will be utilized for all of the
following emission levels and models: 744L FT4, S3a, S2 & 824L FT4, Tier
III.
The system will be located at the rear of the machine in John Deere’s
patented Quad Core configuration. The cooling system will be comprised of
a radiator, charge air cooler (CAC), transmission cooler (TOC), hydraulic
cooler (HOC), two axle oil coolers (AOC), a fuel cooler and an air conditioning
condenser.
The supplier will be responsible to provide heat exchangers that can be
assembled into John Deere’s plenum. The supplier will also be responsible
for adding mounting features to the TOC to attach the fuel cooler and AOC if
a separate condenser is used. John Deere may supply the mounting
fasteners and bracketry for the fuel cooler and condenser (TBD). The
condenser must have swing out accessibility with tool-less access. If the fuel
cooler is relatively small it may be possible to directly mount and not swing to
keep complexity and cost minimal. John Deere design engineer will need to
review and seek approval from peers.
John Deere will be responsible for the fan, fan shroud and the mounting
structure as well as the hoses and tubes connecting to the module. The
supplier may be requested to provide additional mounting provisions for some
Deere assembled components.
4.2. Musts
Though this specification details many design requirements, operating
conditions, and performance requirements, any system design optimization
requires specification compromise. The design requirements listed below
identify the specifications that the system must meet as a minimum (no
compromise):
4.2.1. Meet prototype development and model production schedule.
4.2.2. Meet target cost objectives.
4.2.3. Meet the minimum cooling performance requirements.
4.2.4. Meet durability goals.
4.2.5. Meet warranty goals.
4.2.6. Meet system envelope requirements.
4.3. Wants
The design requirements listed below identify the specifications that
characterize desirable system traits. These specifications may be
compromised during system design optimization.
4.3.1. Minimize total manufacturing cost (TMC).
4.3.2. Maximize trash resistance.
4.3.3. Minimize number of factory options.
4.3.4. Minimize number of service parts.
4.3.5. Minimize fan noise.
4.3.6. Simplify core cleaning.
4.3.7. Maximize serviceability.
5. Identification
5.1. Major serviceable components and assemblies (Radiator, CAC, Fuel cooler,
Transmission Oil Cooler, Hydraulic Oil Cooler, Axle Oil Coolers, Condenser,) must be
permanently identified with the following data:
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 9 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
6. Fluids
6.1. Factory fill fluids
6.1.1. Radiator: John Deere Cool-GardTM II, 50-50 Water-Glycol
6.1.2. Fuel: JDM J12 – Diesel Fuel Specification
6.1.3. Transmission: John Deere Hy–GardTM
6.1.4. Hydraulics: John Deere HydrauTM
6.1.5. Axle: John Deere Hy–GardTM
6.1.6. Condenser: R-134a refrigerant and poly-alkalyne glycol oil (PAG oil
:Nippon Denso Oil-8)
6.2. Allowable fluids (in addition to factory fill fluids)
6.2.1. Radiator: John Deere Cool-Gard II PG, heavy duty diesel engine coolants
with the minimum following chemical and physical properties:
Formulated with a quality nitrite free additive package
Provides cylinder liner cavitation protection according to either the John
Deere Cavitation Test Method or a fleet study run at or above 60% load
capacity
Protects the cooling system metals (cast iron, aluminum alloys, and copper
alloys such as brass) from corrosion
7. Test Documentation
7.1. Prior to EPDP Gate #11, the Engine and Cooling System PV&V plan will be
established. See V2 Net 262522 for the PV&V plan. This plan will list V2 Net numbers
for all testing related to the cooling system. As appropriate, the test activities for the
pressure cycle durability or thermal cycle durability will include the suppliers cooling
system DVP&R and supplier test reports.
8. Application Data
8.1. Vehicle
8.1.1. Type: 4WD Loader
8.1.2. Off level operations:
8.1.2.1. Fore/aft: 30 degrees
8.1.2.2. Side to side: 15 degrees
8.1.3. Vehicle operating ambient temperature range:
8.1.3.1. Minimum: -40°C
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 12 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
8.5.4. Fan control system must consider disengagement of compressor clutch when
a fan reversal occurs.
8.5.5. Fan control system must consider condenser airflow requirements.
8.6. Test Conditions for Cooling System Performance
8.6.1. Reference John Deere Dubuque Engineering Analysis Procedures (EAP)
0400-015 Engine Air System Testing and 0501-002 Cooling System
Performance and Underhood Temperature Testing for specific test conditions.
8.6.2. All heat exchanger performance testing to be conducted “clean” (no external
fouling).
8.6.3. Charge Air Cooler Performance Test
8.6.3.1. Ambient Temperature 25°C
8.6.3.2. Elevation 1000 ft.
8.6.3.3. Vehicle loading Full load rated
speed
8.6.3.3.1. To be accomplished by performing a torque converter
stall and stalling hydraulics over relief, if necessary.
8.6.4. Field Heat Rise
8.6.4.1. Ambient Temperature: >25°C
8.6.4.2. Elevation 1000 ft.
8.6.4.3. Operations
8.6.4.3.1. Loader stockpiling at a rate of 2.0 cycles per minute at
100% fan speed commanded through the vehicle monitor
8.7. Environment and Airborne Contaminants
8.7.1. 744L and 824L 4WD Loaders are considered production machines and are
employed to move a variety of materials. They operate in many environments
from construction to agriculture to waste-handling. Materials commonly found
in those environments include, but are not limited to, dirt, rock, and organic
material. The level of airborne contaminants may be substantial.
Unfortunately, John Deere is currently unable to quantify the airborne
contaminant levels in a meaningful manner. Consequently, Deere and the
supplier are required to consider and make plans for managing these
contaminants based on past experience. Examples of a high-debris
application include the use of 4WD Loaders in forestry, landfills, and loading
mulch.
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 14 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
8.7.2. Typically, the method for dealing with cooling air side fouling of heat
exchanges has been to design spare capacity into the heat exchangers. The
cooling engineering design targets have been set to take this potential fouling
into account.
8.8. Heat Exchanger Considerations
8.8.1. Operating temperatures
8.8.2. Fluid temperatures
8.8.2.1. Radiator
8.8.2.1.1. Minimum fluid temperature -40°C
8.8.2.1.2. Maximum fluid temperature 113°C
8.8.2.2. Fuel cooler
8.8.2.2.1. Minimum fluid temperature -40°C
8.8.2.2.2. Maximum fluid temperature 130°C
8.8.2.3. Charge air cooler
8.8.2.3.1. Minimum fluid temperature -40°C
8.8.2.3.2. Maximum fluid temperature 250°C
8.8.2.4. Hydraulic Oil cooler
8.8.2.4.1. Minimum fluid temperature -40°C
8.8.2.4.2. Maximum fluid temperature 130°C
8.8.2.5. Transmission Oil cooler
8.8.2.5.1. Minimum fluid temperature -40°C
8.8.2.5.2. Maximum fluid temperature 130°C
8.8.2.6. Axle Oil coolers (x2)
8.8.2.6.1. Minimum fluid temperature -40°C
8.8.2.6.2. Maximum fluid temperature 130°C
8.8.2.7. Condenser
8.8.2.7.1. Minimum fluid temperature -40°C
8.8.2.7.2. Maximum fluid temperature 100°C
8.8.3. Package Arrangement
The cooling package will be located in the aft-most portion of the machine as
shown. See Figure 1.
8.8.6. Fin and Tube Material for Radiators, CACs, Condensers and Oil Coolers:
8.8.6.1. Industry standard materials are acceptable.
8.8.6.2. Internal passages for coolant or oil flow shall be free of
materials (i.e. brazing flux) that would precipitate or would
cause other materials in the coolant or oil to precipitate out of
solution, causing internal fouling of the heat exchanger system.
8.8.7. Fin and Tube Material for Fuel Cooler: The following materials must not
contact fuel: copper, bronze, brass, tin, lead, zinc natural rubber, nitrile rubber
and butyl rubber.
8.8.8. Damage Resistance
8.8.8.1. The heat exchanger air-side fins and tubes shall exhibit
resistance to damage from normal cleaning. In general,
minimum fin thickness required to provide adequate strength is
0.08 mm. In the course of normal operations, the vehicle heat
exchangers will require cleaning. Normal cleaning practices
include the use of steam, high pressure air, or high pressure
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 18 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
5.4°C 5.7°C
5.4°C 5.6°C
Fuel
HOC
9.6°C 8.5°C
13.9°C 9.2°C
RAD
8.10. Fan
8.10.1. Diameter: 965.2 mm
8.10.2. Number of blades: 12
8.10.3. Fan weight: 6.35 kg
*For engine speeds other than 2200 rpm, coolant flow can be
estimated by: Q2=Q1*(rpm2/rpm1).
**The values for minimum water pump inlet pressure are absolute
pressures and must be met at the maximum vehicle operating altitude
per section 8.1.4.2.
*** This includes the hoses/tubes and the radiator.
**** This sets the pressure drop budget for the radiator its self.
8.13. Radiator
8.13.1. Design/Redline value used for ATR calculations 113 °C
8.13.2. Overheat sensor location. See Figure Thermostat housing
8.13.3. Performance goal (specify conditions): ATR ≥ 48°C
8.13.4. Engineering target (specify conditions): ATR ≥ 53°C
Coolant heat
Torque
Machine Engine Operating Engine speed Power rejection
model model point (RPM) (kW) (Nm) (kW)
FT4
6090
744L PSS FLRS 2100 198 900
FT4
6090
824L PSS FLRS 2100 230 1045 150
824L FT4 FHR 2000 200.7 1206 130
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 24 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
6090
PSS
Max. Min.
CAC CAC Max. Min.
Intake CAC CAC system system CAC CAC
Engine flow inlet inlet press. press. press. press.
Machine Engine speed Power Torque rate press. temp. drop drop drop drop
model model (RPM) (kW) (Nm) (kg/s) (kPa) (° C) (kPa (kPa) (kPa) (kPa)
FT4
6090
744L PSS 2100 198 900 .3194 214 170 16 8
FT4
824L
6090
PSS 2100 230 1045 .3194 214 190 16 8 11 3
Surge Tank
10. Vehicle composite for Thermal and Pressure Cycle Fatigue Life
Calculations
10.1. The composites used for fatigue life calculations are defined in the following two
Engineering Analysis Procedures (EAP)
10.1.1. 0501-006: Oil Cooler Pressure Cycle Performance and Verification
10.1.2. 0501-008: Thermal Cycle Durability of Heat Exchangers
10.2. These composites used in conjunction with the component tests to failure will be
used to predict fatigue life. Unfortunately, the life prediction cannot be performed until
heat exchangers are built, installed in vehicle for strain or pressure history data
collection and finally a lab test. This method does not provide guidance for the
durability enhancing features that should be incorporated into the design. For this
reason section 11 defines a lab cycle test that can be used to determine which
durability features may need to be included in a design.
10.3. The primary considerations when developing a composite include:
10.3.1. Vehicle work idle cycles. A work idle cycle is defined as operating the
machine under load for 3 minutes or more and then idling the machine for 1
minute or more.
10.3.2. Machine operations that induce a rapid change in heat loads such as
torque converter stalls, retarders, engine brakes, low idle to full load rated
speed operation, etc.)
10.3.3. Frequency of fan reversals
11.5.4. The thermal cycle test parameters can be defined by one of the
following two means. Whichever case is chosen, a strain gauged CAC will be
used to characterize the strains observed during the lab test. The strain gauged
CAC will be removed once characterization is complete and new components
installed for the thermal cycle test.
11.5.4.1. Method 1: Lab strains to duplicate or be higher than strains
that were observed during the vehicle field history. Note: not all
strain gauges will be matched. Supplier and Deere to agree on
strain gauges to match in the lab.
11.5.4.1.1. Test to be performed to a minimum of 10,000 cycles or until
failure. Extension of the test beyond 10,000 cycles may be required to
prove sufficient field life. Failure is define in section as exceeding the
pressure decay rate defined in section 11.5.5.1.
11.5.4.1.2. Inspection interval: 250 – 1000 cycles depending on total cycle
count.
11.5.4.2. Use an accelerated test such as:
11.5.4.2.1. Hot air flow of 1500 kg/hour at 260 + 5 C through
heat exchanger for 90 seconds.
11.5.4.2.2. Cold air flow of 1500 kg/hour at 200 C lower than
the hot temperature through heat exchanger for 90
seconds.
11.5.4.2.3. Maximum temperature rise rate at inlet: 20ºC/sec
11.5.4.2.4. External air flow rate: 0
11.5.4.2.5. Test to be performed to a minimum of 10,000 cycles or until
failure. Extension of the test beyond 10,000 cycles may be required to
meet component B50 goal of 30,933 hours. Failure is define as
exceeding the pressure decay rate defined in Section 11.5.5.1.
11.5.4.2.6. Inspection interval: 250 – 1000 cycles depending on total cycle
count
11.5.5. Fatigue life prediction to meet component B50 goal of 30,933 hours.
11.5.5.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
11.5.6. Pressure Decay
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 37 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
11.5.6.1. Procedure - All inlet and outlets shall be sealed with air-
tight plugs or fittings. A means of introducing compressed air
into the heat exchanger shall be provided. The pressure shall
be measured for 15 seconds after reaching 207 kPa.
11.5.6.2. Maximum Pressure Decay 35 kPa /15 seconds
11.6. Oil Cooler(s) - This section applies to all unique part numbered transmission,
hydraulic, and axle oil coolers.
11.6.1. Test fluid – oil or water/glycol
11.6.2. The thermal cycle test parameters can be defined by one of the
following two means. Whichever case is chosen, a strain gauged oil cooler will
be used to characterize the strains observed during the lab test. The strain
gauged oil cooler will be removed once characterization is complete and new
components installed for the thermal cycle test.
11.6.2.1. Method 1: Lab strains to duplicate or be higher than
strains that were observed during the vehicle field history.
Note: not all strain gauges will be matched. Supplier and Deere
to agree on strain gauges to match in the lab.
11.6.2.1.1. Test to be performed to a minimum of 5,000
cycles or until failure. Extension of the test beyond 5,000
cycles may be required to meet component B50 goal.
Failure is defined as any visible leak.Method 2: Use an
accelerated test such as:
11.6.2.2. Method 2: Use an accelerated test such as:
11.6.2.2.1. Hot oil flow of 3 l/s at 100 + 5 C through heat
exchanger until the outlet temperature stabilizes to within
3 C of the inlet.
11.6.2.2.2. Cold oil flow of 3 l/s at 80 C lower than the hot
temperature through heat exchanger until the outlet
temperature stabilizes to within 3 C of the inlet.
11.6.2.2.3. Maximum Cycle Rate: 1.5 cycles per minute
11.6.2.2.4. Temperature rise rate at inlet: 5ºC/sec
11.6.2.2.5. External air flow rate 0
11.6.2.2.6. Test to be performed to a minimum of 5,000 cycles or until
failure. Extension of the test beyond 5,000 cycles may be required to
meet component B50 goal. Failure is defined as any visible leak.
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 38 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
13.1. All testing to be conducted on heat exchangers that have not been repaired.
13.2. Minimum sample count: 2
13.3. Fluid oil
13.4. Temperature 20 +/- 5°C
13.5. Transmission oil cooler, axle oil cooler, hydraulic oil cooler, and condenser
13.5.1. Connect a pressure source to the inlet port of the heat exchanger.
13.5.2. Plug the outlet port of the heat exchanger.
13.5.3. Elevate the pressure at a constant rate to 400% of working pressure
within a period not less than 15 seconds and hold for 60 seconds and monitor
pressure decay.
13.5.4. Any pressure decay, external leakage, visible permanent deformation
of components or structural cracks warrants a failure.
13.5.5. Continue to increase pressure until heat exchanger fails and record
maximum pressure obtained.
13.6. CAC burst testing is not required
13.7. Radiator Coolant hoses
13.7.1. Connect a pressure source to one end of the hose.
13.7.2. Plug opposite end of hose
13.7.3. Elevate the pressure at a constant rate to the appropriate pressure per
DTW 1223 and SAE J20R4 for the hose diameter of XX mm within a period not
less than 15 seconds and hold for 60 seconds. TBD
13.7.4. Any pressure decay or external leakage warrants a failure.
13.7.5. Continue to increase pressure until hose fails and record maximum
pressure obtained.
13.8. Radiator
13.8.1. Connect a pressure source to the inlet port of the heat exchanger.
13.8.2. Plug the outlet port of the heat exchanger.
13.8.3. Elevate the pressure at a constant rate to 200% of working pressure
within a period not less than 15 seconds and hold for 60 seconds and monitor
pressure decay.
13.8.4. Any pressure decay, external leakage, visible permanent deformation
of components or structural cracks warrants a failure.
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 41 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
13.8.5. Continue to increase pressure until heat exchanger fails and record
maximum pressure obtained.
13.9. Fuel cooler: burst testing of fuel cooler is not necessary pending approval of fuel
cooler construction by John Deere Engineering.
14.7.3. Pressure range #1: 0 kPag - 30% above rated pressure of charge air
cooler
14.7.4. Cycle Count: Test until failure
14.7.4.1. External leakage exceeding Section 20.3.2, visible permanent
deformation of components, or structural cracks warrants a failure.
14.7.5. Air temperature: 225 +/- 5 °C
14.7.6. Maximum cycle rate: 2 cycles/sec
14.7.7. Fatigue life prediction to meet component B50 goal of 30,933 hours.
14.7.7.1. For John Deere internal use only see DTW 2807 Component Durability
Goals Technical Specification for All Products
14.10.6. Pressure profile: 2 sec up, hold for 2 sec, 2 sec down
14.10.7. Life prediction to meet component B50 goal of XX hours.
14.10.7.1.For John Deere internal use only see DTW 2807 Component Durability
Goals Technical Specification for All Products
14.11. CAC circuit tubes/hoses and couplers – test requirements are being developed,
consult engine and cooling PV&V. See V2 Net 98460.
14.11.1. Minimum sample count for each pressure level: 2
14.11.2. Test using production intent clamps, torques and bead geometry
14.11.3. Test Fluid: air
14.11.4. Test pressure 0 kPag - 413 kPag
14.11.5. Test Temperature: 250°C
14.11.6. Cycle Count: Until failure
14.11.6.1.Any external leakage, cuts, tears, perforations, or delaminations
warrants a failure. Permanent deformation or excessive ballooning of
components must be approved by John Deere engineering.
14.11.7. Pressure profile: 2 sec up, hold for 2 sec, 2 sec down
14.11.8. Life prediction to meet component B50 goal of 30933 hours.
14.11.8.1.For John Deere internal use only see DTW 2807 Component Durability
Goals Technical Specification for All Products
23.1.2. In-depth review of current supply base capabilities and supplier end-of-
line visual acceptance criteria should be reviewed prior to print release.
23.1.2.1. This attribute quantification can be achieved by reviewing
supplier specific controlled documents and/or conversations
with your local heat exchanger Supplier Quality Engineer.
23.1.3. It is the responsibility of the cooling system Design Engineer to
communicate with product line stakeholders (quality, product support,
marketing, etc.) and decide upon the acceptance of these visual criteria, with
the understanding that any restrictions in excess of current capability will likely
have an impact on cost
23.1.3.1. Per JDS-G113.1X1 a JD90 print is required and any
exceptions agreed upon in 23.1.3 should be captured in the
drawing notes for both John Deere and supplier drawings.
23.1.3.1.1. Examples
23.1.3.1.1.1. Fin damage not exceed 2% of total core face surface area
23.1.3.1.1.2. No leak repair allowed
23.1.3.2. If it is expected that a part and/or assembly print will be
adopted from the supplier it is required that the supplier related
controlled documentation regarding aesthetics be referenced
in the adopted print’s drawing notes.
25. References
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 51 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification
References:
*Adapted from Design and Development of Automotive Engine Cooling
Systems 1998-by Al Kargilis
** Adapted from SAE SP-1541 A Systems Engineering Approach to Engine
Cooling Design by Peter Kanefsky, Valerie A. Nelson and Mary Ranger –
Ford Motor Company
ASTM 2570
See DVP&R for heat transfer, internal pressure drop and external pressure drop for each
heat exchanger.