X Approved For Supplier Distribution Internal To Deere Only: Worldwide Construction and Forestry Division Specification

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WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION

SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

X APPROVED FOR SUPPLIER DISTRIBUTION


INTERNAL TO DEERE ONLY

Printed or saved copies are considered to be uncontrolled.


Rev Description ECN Date Writer
A New DTW for 744/824L Cooling AD5778YT 18July2017 J. Thole
Package Quoting
B Updated Pressure Cycle Test with CAC AD5778YT 27July2017 J. Thole
B50 information

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 1 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
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

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 2 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

Table of Figures
Figure 1 Cooling System Layout 744/824L ....................................................................... 17
Figure 2 Envelop Dimensions ........................................................................................... 17

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 3 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

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.

2. Supplier Capability Requirements


2.1. All cooling system components referenced in this document shall meet the specified
performance requirements. The supplier shall provide certification where requested.
Although all production components must meet these specifications, it is up to the
supplier's and Deere’s discretion as to which supplier production tests are required to
ensure compliance.
Maintain the test condition accuracy within the following limits:
Test Condition Maintain Within ± of expected value
Pressure 2%
Temperature 1°C
Time 2%
Flow rate 2%
Air flow velocity 5%

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 4 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

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

2.6.12.1. Leak Test


2.6.12.1.1. The supplier shall have the capability to test the
component for external leakage. C&F to provide
parameters for testing.
2.7. Quality
2.7.1. The supplier shall have the capability to perform Process Capability studies
(Cp, Cpk or Pp, PPK) on Product Key Characteristics and a Gage Repeatability
and Reproducibility study on gages/test stands used to monitor Product Key
Characteristics. For details reference JD standard JDS-G 223 – Supplier
Quality Manual.
2.8. Handling/shipping protection to prevent contamination and or damage
2.8.1. Protection must be easily removable without damaging sealing surfaces.
2.8.2. Protection must remain effective during standard handling procedures.
2.8.3. Protection must be such that it cannot be forced into the port ID by hand.
2.8.4. Protection must be such that it has to be removed in order to allow the
installation in the intended assembly.

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

To further explain, assuming that ATR is required to be a minimum of 52°C, T max


is defined as 115°C, and Tamb is determined to be 52°C, then Tmeas must be equal
to 115°C. The implication is that ATR merely indicates the ambient temperature
at which the vehicle may operate without exceeding the maximum operating
temperatures.
3.3. Burst Pressure – a safety factor established for components that is typically four times
working pressure.
3.4. DVP&R – Design Verification Plan and Report – test plan and results for component
testing
3.5. EPDP – Enterprise Product Delivery Process – process used by John Deere to
introduce products to market
3.6. Working pressure: maximum pressure a system is intended to operate at. Often times
working pressures can be exceeded during cold ambient operations.

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.

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 8 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

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

5.1.1. John Deere part number


5.1.2. Supplier name
5.1.3. Supplier part number
5.1.4. Build date

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

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 10 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

6.2.2. Fuel Cooler:


 JDS-G135 Petroleum diesel #1, #2 and blends - USD 15ppm sulfur, ASTM
D975, EN590
 Bio Fuels-B20 with blending stock meeting ASTM D6751. (Refer to JDS-
G135 for complete requirements.)
 Bio Fuels-Rapeseed Methyl Ester-B100 RME EN14214. (Refer to JDS-G135
for complete requirements.
 Jet fuel: JP-8 MIL-DTL-83133E(update or delete as appropriate)
6.2.3. Transmission: John Deere Low Viscosity Hy–GardTM,
John Deere Bio-Hy-GardTM II, oils meeting John Deere Standard JDM J20
6.2.4. Hydraulic: John Deere HydrauTM XR, John Deere Plus-50TM II 10W30, 15W30
and 0W40, John Deere Plus-50 TM 10W30, 15W40 and 0W40, ISO VG 32, ISO
VG 46, John Deere Hydrau-GardTM 46 Plus and John Deere Hydrau-Gard
ArticTM 22, oils meeting minimum API Service classification CI-4, Anit-Wear
Hydraulic Oil (AWHO), ISO 11158 Category HV and DIN 51524-3
6.2.5. Axle: John Deere Low Viscosity Hy–GardTM,
John Deere Bio-Hy-GardTM II, oils meeting John Deere Standard JDM J20
6.2.6. Air Conditioning Condenser: See factory fluids
6.3. Test Fluids: Supplier and Deere to agree upon test fluids used for each test being
performed. Fluids will be specified in the appropriate sections of this document.
6.4. Fluid compatibility
6.4.1. Heat exchangers must be compatible with fluids listed in sections 6.1, 6.2 and
6.3.
6.5. Certain types of manufacturing processes can interact in an adverse way with coolant.
6.5.1. Coolants to be tested include
6.5.1.1. Cool GardTM II
6.5.1.2. ASTM-D6210
6.5.1.3. Factory-fill anti-freeze/coolant must be heavy-duty ethylene
glycol or propylene glycol.
6.5.1.3.1. Coolants with higher concentration of water than anti-
freeze can cause erosion. Careful consideration must be
given to the test plan.

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 11 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

6.5.1.3.1.1. North American water to coolant mixtures are typically


50/50, but some regions may use up to an 80/20 ratio.
6.5.1.3.2. Reference coolant specification RGS50012
6.5.1.3.3. All coolant must comply with JDS-G135
6.6. Charge Air Cooler Internal Air
6.6.1. See Section 8.14
6.7. External airflow (cooling airflow)
Results should be documented as actual cubic meters per second, with documented
barometric pressures and temperatures so a mass flow can be calculated.
6.7.1. Standard Air – AMCA 200-95
6.7.1.1. Standard air density 1.2 kg/m3
6.7.1.2. Standard absolute viscosity 18.19E-06 N-s/m2
6.7.1.3. Standard temperature 25°C
6.7.1.4. Standard relative humidity 50%
6.7.1.5. Standard barometric pressure 101 kPa
6.7.1.6. Standard specific heat ratio 1.4

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

8.1.3.2. Maximum: 48°C


8.1.4. Vehicle operating elevation range:
8.1.4.1. Minimum: 0 ft.
8.1.4.2. Maximum: 10,000 ft.
8.1.5. Duty cycle Production Loader:
8.1.5.1. Stockpiling / Truck Loading 60%
8.1.5.2. Transport / Load & Carry
29%
8.1.5.3. Misc. (Excavate, Backdrag, Grade, etc.) 6%
8.1.5.4. Idle 5%
8.2. Engine 744L
8.2.1. Model: FT4 9.0L PSS
8.2.2. Rated speed: 2100 rpm
8.2.3. Rated Power: 198 kW
8.2.4. Peak torque speed: 1500 rpm
8.3. Engine 824L
8.3.1. Model: FT4 9.0L PSS
8.3.2. Rated speed: 2100 rpm
8.3.3. Rated Power: 230 kW
8.3.4. Peak torque speed: 1500 rpm
8.4. Fan
8.4.1. Diameter: 965.2 mm
8.4.2. # of blades: 12
8.5. Fan drive will be a hydraulic drive with optional reversing capability
8.5.1. Factory default frequency of fan reversals is once every 30 minutes and can
be adjusted in 5 minute increments from 20 to 40 minutes.
8.5.2. The maximum allowed manual reversal frequency by the vehicle is a reversal
every 1 minute.
8.5.3. Fan control system must command for maximum fan speed when the coolant
temperature at the engine coolant temperature sensor reaches 101°C.
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 13 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

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 15 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

The cooling package will be located in the aft-most portion of the machine as
shown. See Figure 1.

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DATE: 2017-07-27 VERSION: JD90 16 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

Figure 1 Cooling System Layout 744/824L

8.8.4. Air-side Fin Density and Type


8.8.4.1. Maximum fin density is 10.5 fins per inch.
8.8.4.2. To facilitate an even air flow distribution for coolers that are
parallel fin density should be equal or similar.
8.8.4.3. Fins may not be louvered.
8.8.5. Maximum heat exchanger size including tanks. See Figure 2.0 and 3.

Figure 2 Envelop Dimensions

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 17 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

Figure 3 Envelop Dimensions

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

water. Pressure washing testing will be conducted per EAP


9009-004: Cooling Package Power Wash Test Procedure. No
fin damage is allowed.
8.9. Cooling System Airflow, Airflow Direction and Air Inlet Temperature Rise
8.9.1. The fan is a suction fan immersed in a sheet metal shroud. Air is drawn in
through the inlet screens on the side and top of the enclosure and then through
the heat exchanger package. The fan exhausts through the grille screen at the
rear of the machine. See Figure .
8.9.2. A temperature rise above the ambient temperature is assumed due to
recirculation. This increase is applied at each inlet plane and each inlet plane is
broken into sub-sections. Take into account vehicle layout, air flow direction,
gaps in sealing, external recirculation, etc. See Figure 4. Superimpose the
temperature tables in Figures 5-8 below on the zones indicated in Figure 4
(Over/Under and Side by Side tables represent orientation of the temperature
measurements). Thermocouples are located in the center of their associated
zone in the grid.

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DATE: 2017-07-27 VERSION: JD90 19 of 55
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744/824L Cooling System Performance Specification

Figure 4 Cooling Package Airflow Layout

Figure 5 Steady state pre-heats for Zone 1 (TOC/FUEL)


5.8°C 6.0°C
5.4°C 5.3°C
TOC

5.4°C 5.7°C

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DTW 3806
744/824L Cooling System Performance Specification

5.4°C 5.6°C
Fuel

Figure 6 Steady state pre-heats for Zone 2 (RAD/HOC)


2.7°C 10.8°C
2.8°C 3.7°C

HOC

9.6°C 8.5°C
13.9°C 9.2°C
RAD

Figure 7 Steady state pre-heats for Zone 3 (Condenser/AOC stacked)


4.3°C 5.3°C
4.4°C 5.3°C

Figure 8 Steady state pre-heats for Zone 4 (CAC)


3.3°C 2.8°C
3.7°C 2.5°C

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

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8.10.4. Fan rotational inertia: kg*m2


8.10.5. Maximum fan unbalance g*cm
8.10.6. Maximum fan thrust in fan forward direction with 20°C fan inlet air
temperature at maximum fan speed: xx N
8.10.7. Maximum fan thrust in fan reverse direction with 20°C fan inlet air
temperature at maximum fan speed: xx N

8.10.8. Fan immersion (amount of fan inside shroud): 50%


8.10.9. Maximum fan speed (744L) 1700 rpm
8.10.10. Maximum fan speed (824L) 1800 rpm
8.10.11. Estimated cooling system air flow at maximum fan speed and
maximum pressure drop across total system = 1.5 kPa
8.10.11.1.5.0 m3/s
8.10.11.1.1. ΔP Heat Exchangers = 1.0 kPa
8.10.11.1.2. ΔP vehicle installation = 0.5 kPa
8.11. Variable Speed Fan Drive Control Logic
8.11.1. Fan drives with software control
Table 1 Fan control software logic
System At or below this At or above this Comments
value, command value, command
minimum fan maximum fan
speed speed
Radiator 90°C 101°C
CAC (Outlet) 39.5°C@≤25°Camb 52°C@≤25°Camb Allowed +1° for
every additional
degree above 25°C
amb
Fuel N/A N/A
Transmission 82°C 102°C
Hydraulic 63°C 96°C
Axle 90°C 100°C

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744/824L Cooling System Performance Specification

AC 1800 kPa 2000 kPa Compressor


Discharge Pressure

8.12. Water Pump Flow and Pressure Requirements


8.12.1. Coolant mix: 50/50 (water glycol)
8.12.2. Maximum Water Pump Inlet Pressure:235 kPa absolute
@ 113°C top tank temperature
Table 2 Expected Coolant Flows, Minimum Water Pump Inlet Pressures and Maximum
Radiator Pressure Drops
Minimum Minimum Maximum Minimum
water pump water coolant Maximum coolant
inlet pump circuit radiator circuit
pressure at inlet pressure pressure pressure
redline pressure drop at drop at drop at
Engine Expected
(113°C)** at 95°C** ≥98°C*** 95°C**** ≥98°C***
Machine Engine speed radiator
model model (RPM) flow (l/s)* (kPa-abs) (kPa-abs) (kPag) (kPag) (kPag)
FT4
6090
15
744/824L PSS 2200 7.3 168 105 60 40 estimate

 *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

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8.13.5. Maximum shutdown top tank temperature 113 °C Reference


JDPS app guidelies sec B1 Doc.
8.13.6. Coolant warning light activation 110 °C
8.13.7. Nominal pressure cap setting 125 kPa
8.13.7.1. Cap to be supplied by vendor installed on surge tank. If
installed on surge tank, radiator pressure will be approximately
35 kPa higher than pressure cap setting depending on the
coolant pressure drop of the radiator.
8.13.8. Guideline for selecting radiator construction to meet durability
requirements: 0-160 kPa for 50,000 cycles
8.13.9. Fittings
8.13.9.1. Inlet/Outlet: 2.5 in (63.5 mm) OD beaded pipe
8.13.9.1.1. SAE J1231 – Type 2
8.13.9.2. Fill Neck of radiator not required (fill through surge tank)
8.13.9.3. Drain port thread: -6, M16x1.5 ORB
8.13.9.4. Drain port fitting: Petcock
8.13.9.5. Vent line: -4, M12x1.5 ORB
8.13.9.6. Vent line fitting: 7.94 mm (5/16 in.) OD beaded
8.13.9.6.1. SAE J1231 -Type 2
8.13.10. Engine Coolant Heat Rejection Information

Table 3 Engine Coolant Heat Rejection

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
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744/824L Cooling System Performance Specification

6090
PSS

Figure 9 Typical Coolant System Layout

8.14. Air to Air Charge Air Cooler (CAC)


8.14.1. At standard condition (25°C and 1000 ft. elevation)
Air throttle inlet 52°C
8.14.1.1. Performance goal: Intake Manifold Inlet – Amb <
27 °C
8.14.1.2. Engineering target: Intake Manifold Inlet – Amb <
20 °C
8.14.2. At any ambient condition maximum intake manifold 88°C
(Warning light activation and derate)
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744/824L Cooling System Performance Specification

8.14.3. Sensor location see Figure Air throttle inlet


8.14.4. Maximum inlet temperature 225°C
8.14.5. Maximum inlet pressure 225 kPa
8.14.6. Fittings: Inlet/outlet: 76.2 mm (3 in ) OD beaded
8.14.6.1. SAE AS5131 style B
8.14.7. Engine Charge Air Cooler Heat Rejection and Pressure Drop
Information
Table 4 CAC Heat Rejection CAC System and CAC Pressure Drop Requirements

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

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Figure 10 Typical CAC System Layout

8.1. Fuel Cooler


8.1.1. Maximum fuel flow rate 1.56 kg/min
8.1.2. Maximum cooler internal pressure drop 30 kPa
8.1.2.1. @ fuel temperature 80°C
8.1.2.2. @ flow rate 1.56 kg/min
8.1.2.3. Guideline for selecting fuel cooler construction to meet durability
requirements: 0-100 kPa for 1,000,000 cycles
8.1.3. Maximum inlet temperature 83°C

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8.1.4. Overheat sensor location High Pressure Pump


8.1.5. Approximate fluid temperature increase from the fuel cooler outlet to the High
Pressure Pump inlet (heat load contribution from the vehicle excluding the
engine fuel system) 5°C
8.1.6. Redline value used for ATR calculations 80°C
8.1.7. Minimum ATR: 48°C
8.1.8. Engineering Target: 53°C
8.1.9. Fittings: Inlet/Outlet: 9.52 mm (3/8 in.) beaded tube
8.1.9.1. SAE J1231 – Type 3
8.2. Transmission Oil Cooler
8.2.1. Working pressure
8.2.1.1. Normal Operation 300 kPa
8.2.1.2. Peak Normal Operating Pressure (Cold Ambient) 800 kPa
8.2.1.3. Guideline for selecting transmission oil cooler construction to meet
durability requirements: 0-1400 kPa for 1,000,000 cycles
8.2.2. Minimum burst pressure 4000 kPa
8.2.3. Maximum flow rate @ 93°C 1.93 L/s
8.2.4. Maximum pressure drop @ 93°C 241 kPa
8.2.5. Max. Stabilized oil temperature at sump 110°C
8.2.6. Overheat sensor location. See Figure Trans sump
8.2.7. Redline value used for ATR calculations 110°C
8.2.8. Performance goal (FHR Operation): ATR > 48°C
8.2.9. Engineering Target (FHR Operation): ATR > 53°C
8.2.10. Heat rejection
8.2.10.1. Stockpile operation (544)
8.2.10.1.1. Heat rejection: 74 kW
8.2.10.1.2. Oil flow rate: 1.5 l/s
8.2.11. Fittings
8.2.11.1. Inlet/Outlet: M33x2 per ISO 6149

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Figure 11 Typical TOC System Layout

8.1. Hydraulic Oil Cooler


8.1.1. Working pressure
8.1.1.1. Normal Operation 300 kPa
8.1.1.2. Peak Normal Operating Pressure (Cold Ambient) 800 kPa
8.1.1.3. Guideline for selecting hydraulic oil cooler construction to meet
durability requirements: 0-1400 kPa for 1,000,000 cycles

8.1.2. Minimum burst pressure 4000 kPa


8.1.3. Maximum flow rate @ 80°C 2.5 L/s
8.1.4. Maximum pressure drop @ 80°C 345 kPa
8.1.5. Maximum stabilized oil temperature at oil cooler inlet 104°C
8.1.6. Overheat sensor location. See Figure Hydraulic filter header
8.1.7. Redline value used for ATR calculations 104°C
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8.1.8. Performance goal (FHR Operation): ATR > 48°C


8.1.9. Engineering Target (FHR Operation): ATR > 53°C
8.1.10. Heat rejection
8.1.10.1. Stockpile operation
8.1.10.1.1. Heat rejection: 19 kW
8.1.10.1.2. Oil cooler flow rate: 1.5 l/s
8.1.10.1.3. Total system oil flow rate 3.4 l/s
8.1.11. Fittings
8.1.11.1. Inlet/Outlet: M33x2 per ISO 6149

Figure 12 Typical Hydraulic System Layout

8.1. Axle Oil Cooler


8.1.1. Working pressure

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8.1.1.1. Normal Operation 500 kPa


8.1.1.2. Peak Normal Operating Pressure (Cold Ambient) 3500 kPa
8.1.1.3. Guideline for selecting axle oil cooler construction to meet durability
requirements: 0-1400 kPa for 1,000,000 cycles
8.1.2. Minimum burst pressure 14000 kPa
8.1.3. Maximum flow rate @ 121°C 0.238 L/s
8.1.4. Maximum pressure drop @ 121°C 350 kPa
8.1.5. Maximum stabilized oil temperature at oil cooler inlet 120°C
8.1.6. Overheat sensor location. See Figure AOC Inlet
8.1.7. Redline value used for ATR calculations 120°C
8.1.8. Performance goal (High Energy Braking Test): ATR > 48°C
8.1.9. Engineering Target (High Energy Braking Test): ATR > 53°C
8.1.10. Heat rejection
8.1.10.1. High Energy Braking Operation
8.1.10.1.1. Heat rejection: 13 kW per Axle (2 Axles)
8.1.10.1.2. Oil flow rate: 0.246 l/s
8.1.11. Fittings
8.1.11.1. Inlet/Outlet: Front Cooler -8 ORS Fitting Style A 13/16-16 Threads
8.1.11.2. Inlet/Outlet: Rear Cooler -10 ORS Fitting Style A 13/16-16 Threads

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Figure 13 Typical Axle System Layout


8.1. Air Conditioning Condenser
8.1.1. Ambient temperature 43°C
8.1.2. Relative humidity 30%
8.1.3. Heat Rejection (estimated) 12 kW
8.1.4. Refrigerant mass flow rate 50.4 g/s
8.1.5. Target inlet pressure 1800 kPag
8.1.6. Maximum inlet pressure 2070 kPag
8.1.7. Inlet temperature (air) 51°C (Pre-Heat < 8 C)
8.1.8. Refrigerant super heat: 30°C
8.1.9. Refrigerant sub cooling: 6°C
8.1.10. Working Pressure: 2068 kPa
8.1.11. Maximum Pressure: 4140 kPa
8.1.12. Minimum Burst Pressure: 8270 kPa
8.1.13. Minimum Operating Temperature: -40°C

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8.1.14. Maximum Operating Temperature: 107°C


8.1.15. Fittings per DTW 1046 Tube and Hose Fittings, Air Conditioner
Refrigerant
8.1.15.1. Inlet: ¾-16 UNF-2A Male Tube-O Fitting (Long Pilot)
8.1.15.2. Outlet: 5/8-18 UNF-2A Male Tube-O Fitting (Long Pilot)
8.2. Surge Tank (size chosen using E&C PV&V recommendations)
8.2.1. A surge tank shall be used to aide in meeting the fill rate, de-aeration,
drawdown, coolant expansion requirements and maintain system pressure
8.2.2. Capacity 8L
8.2.3. Expansion volume (% of system capacity) 10%
8.2.4. Coolant loss sensor is required
8.2.5. Fittings
8.2.5.1. Pressure cap: SAE 18 psi
8.2.5.2. Vent lines 8.15 mm nominal OD
8.2.5.3. Return to water pump 33.8 mm nominal OD

Pressure cap To atmosphere

Surge Tank

Radiator Engine Water Pump


thermostat
Housing

Figure 14 Surge Tank Vent and Return Schematic


8.1. Shroud
8.1.1. Shroud construction will be of steel.
8.1.2. Shroud type will be box
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8.1.3. Finger guard will be mounted to shroud with 6 mounting points


8.2. Finger Guard
8.2.1. Finger guard to meet requirements of ISO 3457 - Earth Moving Machinery -
Guards
8.2.2. Will be single piece construction
8.3. Radiator hoses
8.3.1. Adhere to DTW 1223 Radiator and Heater Hose Specification which
references SAE J20
8.3.2. Working pressure: 180 kPa
8.3.3. Minimum burst pressure per DTW 1223
8.3.4. Working pressure not to exceed ½ of burst pressure
8.3.5. Must Meet Pressure Cycle Test of 5-35PSI (kPa) 100,000 cycles

9. Fill Rate, De-aeration, and Draw-down


9.1. Cooling system shall fill to 90% of system capacity minimum at 11 l/min with production
engine/thermostat(s) per EAP 0400-011 (Engine Cooling System Application Approval
Testing (System Capacity, Fast Fill, De-aeration, Water Pump Inlet Pressure and
Radiator Pressure Drop, Drawdown and Coolant Circuit Pressure History).
9.2. Cooling system must purge all entrained air within 25 minutes after initial fill and one
hot shutdown followed by 25 additional minutes of operation per EAP 0400-011.
9.3. Cooling system design must maintain de-aeration under all modes of operation
including off level. In level operating conditions, coolant loss switch must activate at 2%
coolant volume prior to aeration occurring. See DTW 2378 for additional requirements
of the off level operation. To be tested per EAP 0400-011.
9.4. Test fluid: clear coolant per EAP 0400-011

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

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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. Thermal Cycle Test


11.1. All testing to be conducted on heat exchangers that have not been repaired.
11.2. If a combination cooler, specify each section and test each section at its own
condition.
11.3. Lab thermal cycle durability tests can be accelerated two ways:
11.3.1. 1. Faster cycle rates than what can be obtained in the field. This
means of accelerating the test is almost always obtainable.
11.3.2. 2. Strain ranges in the lab that are higher than the field. This means of
accelerating the test is frequently possible, but not always.
11.4. Radiator
11.4.1. Test fluid: Water or Water/Glycol Mix
11.4.2. Minimum sample count: 3 (2 for testing to failure and 1 for strain
gauging)
11.4.3. Max cycle rate of: 1.5 cycles per minute
The thermal cycle test parameters can be defined by one of the following two
means. Whichever case is chosen, a strain gauged radiator will be used to
characterize the strains observed during the lab test. The strain gauged radiator
will be removed once characterization is complete and new components
installed for the thermal cycle test.
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11.4.3.1. 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.
11.4.3.1.1. 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 of
30,933 hours. Failure is define as a leak occurs.
11.4.3.1.2. Inspection interval: 200-500 cycles
11.4.3.2. Method 2: Accelerated test such as:
11.4.3.2.1. Hot water flow of 4 l/s at 100 + 5 C through heat
exchanger until the outlet temperature stabilizes to within
3 C of the inlet.
11.4.3.2.2. Cold water flow of 4 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.
11.4.3.2.3. Temperature rise rate at inlet: 5ºC/sec
11.4.3.2.4. External air flow rate: 0
11.4.3.2.5. Test to be performed to a minimum of 5,000 cycles or until
failure. Failure is define as a leak occurs. Extension of the test beyond
5,000 cycles may be required to prove sufficient field life.
11.4.3.2.6.
11.4.3.2.7. Inspection interval: 200-500 cycles
11.4.4. Fatigue life prediction to meet component B50 goal of 30,933 hours.
11.4.4.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
11.5. Air to Air Charge Air Cooler
11.5.1. Test Fluid: Air
11.5.2. Minimum sample count: 3 (2 for testing to failure and 1 for strain
gauging)
11.5.3. Maximum cycle rate: 1.5 cycles per minute

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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
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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.
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11.6.3. Transmission oil cooler fatigue life prediction to meet component B 50


goal of 44,333 hours.
11.6.3.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
11.6.4. Hydraulic oil cooler fatigue life prediction to meet component B 50 goal
of 44,333 hours.
11.6.4.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
11.6.5. Axle oil cooler fatigue life prediction to meet component B50 goal of
44,333 hours. This may not be necessary for copper round tube or steel round
tube coolers.
11.6.5.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
11.7. Fuel Cooler
11.7.1. Historical evidence has shown that the thermal cycles from the engine
are minimal, and thermal cycle testing of the fuel cooler has not been required.
If the following requirement is met, then no thermal cycle testing is required:
11.7.2. The supplier has previously provided Deere with production fuel
coolers of similar construction (i.e. Bar-Plate, Tube-Fin, etc.) and has
completed a DVP&R (consult your Engine & Cooling PV&V Engineer).
11.7.3. If the fuel cooler fails to satisfy the above requirement, please consult
your Engine & Cooling PV&V Engineer for specific lab thermal cycle
requirements.
11.8. Condenser
11.8.1. If existing supplier with existing technology and life has been
demonstrated with other applications and application conditions are similar, that
is similar (pressures and flow) testing is not required.
11.8.2. If new supplier or new technology, durability must be proven.

12. Pressure Drop Test (internal fluid)


12.1. Radiator
12.1.1. Fluid: 50/50 water glycol
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12.1.2. Fluid temperature 95 °C (Utility 98)


12.1.3. Measure and provide pressure drop curve vs. coolant flow rate
12.1.4. Pressure drop at maximum flow rate shall not exceed limit stated in
Section 8.12.
12.2. Transmission Oil Cooler, Axle Oil Coolers and Hydraulic Oil Coolers
12.2.1. Fluid: Factory fill fluids appropriate to the cooler
12.2.2. Measure and provide pressure drop curve vs. oil flow rate for the
following temperatures:
12.2.2.1. 66°C
12.2.2.2. 82°C
12.2.2.3. 104°C
12.2.3. Pressure drop at maximum flow rate shall not exceed
12.2.3.1. Transmission See Section 8.2.4
12.2.3.2. Hydraulic: See Section 8.1.4
12.2.3.3. Axle: See Section 8.1.4
12.3. Charge Air Cooler (Internal pressure drop)
12.3.1. Fluid: air
12.3.1.1. Inlet temperature: 190°C
12.3.1.2. Inlet pressure 214kPa
12.3.1.3. Outlet temperature 52°C
12.3.2. Measure and provide pressure drop curve vs. air flow rate
12.3.3. Pressure drop at maximum flow rate shall not exceed limit per Section
8.14.7.
12.4. Fuel Cooler
12.4.1. Fluid: need a fluid that matches the viscosity of #2 diesel at 70°C
12.4.2. Measure and provide pressure drop curve vs. flow rate.
12.4.3. Pressure drop at maximum flow rate shall not exceed limit per Section
8.1.2

13. Burst Test

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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.
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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. Pressure Cycle Tests


14.1. Definitions
14.1.1. Rated pressure: confirmed through testing at which the heat
exchanger is designed to operate for a number of repetitions
14.2. All testing to be conducted on heat exchangers that have not been repaired.
14.3. If a combination cooler, specify each section and test each section at its own
condition
14.4. Radiator
14.4.1. Minimum sample count for each pressure tested: 2
14.4.2. Test Fluid: 50/50 water glycol
14.4.3. Pressure range #1: 0 kPag - 160 kPag
14.4.4. Cycle Count: Test until failure
14.4.4.1. Any external leakage, visible permanent deformation of
components, or structural cracks warrants a failure.
14.4.5. Pressure range #2: 0 kPag - 207 kPag
14.4.6. Cycle Count: Test until failure
14.4.6.1. Any external leakage, visible permanent deformation of
components, or structural cracks warrants a failure.
14.4.7. Coolant Temperature: 113 +/- 5°C
14.4.8. Pressure profile: 2 sec up, hold for 2 sec, 2 sec down
14.4.9. Fatigue life prediction to meet component B50 goal of 30,933 hours.
14.4.9.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
14.4.10. Guideline for selecting radiator construction to meet durability
requirements: 0-160 kPa for 50,000 cycles
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14.5. All Oil Coolers


14.5.1. Minimum sample count for each pressure level: 2 per pressure
range
14.5.2. Test fluid: Oil
14.5.3. (Pressure range #1: 0 kPag - 30% above rated pressure of oil
cooler
14.5.4. Cycle count: Test until failure
14.5.4.1. Any external leakage, visible permanent deformation of
components, or structural cracks warrants a failure.
14.5.5. Pressure range #2: 0 kPag - 60% above rated pressure of oil
cooler
14.5.6. Cycle count: Test until failure
14.5.6.1. Any external leakage, visible permanent deformation of
components, or structural cracks warrants a failure.
14.5.7. Oil temperature: 90 +/- 5°C
14.5.8. Maximum cycle rate of 5 cycles/sec
14.5.9. Fatigue life prediction to meet component B50 goal of 44,333 hours.
14.5.9.1. For John Deere internal use only see DTW 2807
Component Durability Goals Technical Specification for All
Products
14.6. Condenser
14.6.1. Minimum sample count: 2
14.6.2. Pressure range: 0-2930 kPag
14.6.3. Cycle Count: Minimum 100,000 or until failure
14.6.4. Fluid temperature: 90 +/-5 °C
14.6.5. Maximum cycle rate: 4 cycles/sec
14.6.5.1. Any external leakage, visible permanent deformation of
components, or structural cracks warrants a failure.
14.7. CAC
14.7.1. Minimum sample count for each pressure level:2 per pressure range
14.7.2. Test fluid: Air
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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

14.8. Fuel Cooler


Historical evidence has shown that the pressures imparted from the fuel system on
the fuel cooler are negligible compared to the pressure cycle durability
demonstrated on currently purchased fuel coolers. If both of the following
requirements are met, then no pressure cycle testing is required:
14.8.1. The supplier has previously provided Deere with production fuel
coolers of similar construction (i.e. Bar-Plate, Tube-Fin, etc.) and has
completed a DVP&R (consult your Engine & Cooling PV&V Engineer for list of
suppliers)
14.8.2. The fuel system meets JDPS Engine Application Requirements for
Fuel System Return Pressures (inlet pressures to the fuel cooler typically
should be <40 kPa)
14.8.3. If the fuel cooler fails to satisfy both of the above requirements, consult
your Engine & Cooling PV&V Engineer for specific lab pressure cycle
requirements.
14.8.3.1. Minimum sample count for each pressure level: 2
14.8.3.2. Test fluid: oil
14.8.3.3. Pressure range #1: 30% above design pressure of fuel
cooler
14.8.3.4. Cycle count: Test until failure

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14.8.3.4.1. Any external leakage, visible permanent


deformation of components, or structural cracks warrants
a failure
14.8.3.5. Pressure range #2: 60% above design pressure
of fuel cooler
14.8.3.6. Cycle count: Test until failure
14.8.3.6.1. Any external leakage, visible permanent
deformation of components, or structural cracks warrants
a failure
14.8.3.7. Oil temperature: 90°C +/-5
14.8.3.8. Maximum cycle rate of 4 cycles/sec
14.8.3.9. Fatigue life prediction to meet component B50 goal of
50,000 hours.
14.8.3.10.For John Deere internal use only see DTW 2807 Component Durability
Goals Technical Specification for All Products
14.9. Surge tank (for reference see V2 Net 92454)
14.9.1. Minimum sample count 2
14.9.2. Test Fluid: 50/50 water glycol
14.9.3. Pressure range #1: 0 kPag - 140 kPag
14.9.4. Minimum Cycle Count: 50,000
14.9.5. Coolant Temperature: 120 +/- 5°C
14.9.6. Pressure profile: 2 sec up, hold for 2 sec, 2 sec down
14.10. Coolant hoses – see SAE J1927, consult engine and cooling PV&V. Also see V2
Net 205776. TBD as Coolant hose guidelines are being reworked.
14.10.1. Minimum sample count for each pressure level: 2
14.10.2. Test Fluid: 50/50
14.10.3. Pressure range #1: 0 kPag - 124 kPag
14.10.4. Cycle Count: Until failure
14.10.4.1. Any external leakage will result in rejection of the test
sample.
14.10.5. Coolant Temperature: 120 +/- 5°C

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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

15. Shock/ Vibration Tests


15.1. All testing to be conducted on heat exchangers that have not been repaired.
15.2. ADV (accelerated design verification) Testing
15.2.1. Test shall be performed on a 6 degrees of freedom ADV rig.
15.2.2. The cooling package assembly, in its entirety, shall be mounted using
the cooling package mounts that will be used in the vehicle. This will ideally be
done using part of the vehicle frame as the fixture.
15.2.3. The drive files used for the test shall replicate the motion the vehicle
experiences during field operations. The test will be run to the equivalent of the
B50 life as specified by DTW 3529 Structure Durability Goals Technical
Specification for All Products.

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15.3. Monitoring heat exchangers for leaks


15.3.1. Radiators should be filled with water or water/glycol and pressurized
to 69 kPa
15.3.2. Oil coolers should be filled with water, water/glycol or oil and
pressurized to 69 kPa.
15.3.3. Condensers should be pressurized to 689 kPa using nitrogen.
15.3.4. CAC’s will be pressurized to 69 kPa during the test. It is reasonable to
expect a leak down on the CAC. If the CAC has greater than 20% of the charge
pressure loss in one day of testing after resetting the charge then a pressure
decay test will be performed weekly and at the inspection period closest to the
hour goal for the cooling package.
15.3.4.1.1. Pressure decay 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.
15.3.4.1.2. Maximum Pressure Decay 35 kPa /15 seconds
15.4. Post test inspection
15.4.1. Throughout the test, if the radiator, oil coolers and condenser have
maintained 80% of the charge pressure across two days of testing after
resetting the charge, no leak testing will be performed. This allows for non-
production intent fitting to leak.
15.4.2. If the radiator, oil coolers and condenser have not maintained pressure
a dunk test will be performed.
15.4.3. Any heat exchanger with a potential failure should be sent back to the
supplier for leak testing, and if appropriate failure analysis.
15.5. Guideline for the cooling package design to meet durability requirements: 10g drop
test to 50,000 cycles. The drop test was performed by the supplier on the cooling
system assembly. The assembly was mounted to a fixture that pivoted on one end
and the other end of assembly was raised and dropped to obtain an acceleration of
10g’s on the top of the cooling package. This test has been replaced by the ADV test.

16. External Corrosion


16.1. All testing to be conducted on parts that have not been repaired; See Section 23.
16.2. Sea Water Acid Accelerated Test (SWAAT) - ASTM G85 Annex 3
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16.2.1. 4.2 % Synthetic sea salt - ASTM D1141 at 49°C


16.2.2. pH 2.8 - 3.0
16.2.3. 30 minutes salt spray / 90 minutes hold @ 98% Rel. humidity - test
units to failure
16.3. Goal: Heat exchangers must not leak after 400 hour (200 cycles)

17. Internal Erosion Corrosion for Radiators


17.1. Ensure radiator connection ports and tube velocities are below supplier
recommendations.
17.2. Because the internal erosion/corrosion is dependent on the coolant formulation,
John Deere Coolant must be used for this test. See Appendix A for additional
discussion and references.

18. Cleaning Requirements for External Fouling


18.1. Heat exchangers must withstand pressure washing without fin damage as stated in
EAP 9009-004 Power Washing.

19. In Vehicle Customer Reparability Requirements


19.1. Radiator Remove and replace in 5 hours
19.2. Transmission Oil Cooler Remove and replace in 2.5 hours
19.3. Axle Oil Cooler Remove and replace in 2.5 hours
19.4. Hydraulic Oil Cooler Remove and replace in 5 hours
19.5. Condenser Remove and replace in 1.5 hours
19.6. Fuel Cooler Remove and replace in 1.5 hours
19.7. CAC Remove and replace in 1.5 hours

20. End of Line (EOL)


20.1. All heat exchangers are to be leak tested per appropriate means for the construction
of the heat exchanger. Typical methods include: air under water, pressure decay or
Helium detection.

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20.2. No Leakage is allowed except for CAC’s.


20.3. Supplier and Deere to discuss and agree upon a leak test method and criteria. To
be documented in a supplier document, not in this document. The preferred
documentation location is the drawing. An alternate location would be the DVP&R.
20.3.1. Radiator:
20.3.2. CAC:
20.3.3. Fuel cooler:
20.3.4. Transmission oil cooler:
20.3.5. Hydrostatic oil cooler:
20.3.6. Hydraulic oil cooler:
20.3.7. Axle oil cooler:
20.3.8. Condenser:

21. Cleanliness Requirements


21.1. Cleanliness requirements are to be called out in drawing notes. For example:
Cleanliness per JDS-G242.4 class x
Total internal volume = x.xx m3
Maximum allowable mass contaminant = x.x mg
Absolute maximum, particle size = xx mm (only include max particle
size on drawing if deemed necessary for the application)
21.2. Gravimetric contamination level determination to be performed per John Deere JDQ
64
21.3. Radiator
21.3.1. Contaminants shall conform to cleanliness per JDS G242.4 class E.
21.4. Charge Air Cooler
21.4.1. CAC shall conform to cleanliness per JDS G242.4 class D
21.5. Fuel Cooler

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21.5.1. Contaminants shall conform to cleanliness per JDS-G242.4 class C.


21.5.2. Fuel cooler core (internal) must be void of water and /or halogenated
cleaning solvents.
21.6. Transmission/hydrostatic/hydraulic and axle oil cooler(s)
21.6.1. Contaminants shall conform to cleanliness per JDS-G242.4 class C.
21.6.2. Oil cooler cores (internal) must be void of water and/or halogenated
cleaning solvents
21.7. Condenser
21.7.1. Condensers shall conform to cleanliness standards class 6.4 per JDS-
G226

22. Manufacturing Quality Requirements


22.1. All sealing surfaces shall be free of visible defects and fall within geometrical
nominal dimensions and tolerance standards of fluid sealing surfaces.
22.2. All mounting surfaces shall be free of weld spatter and shall fall within John Deere
specified dimensions and geometric tolerances.
22.3. All internal and external threads, bores, and ports shall be free of weld spatter.
22.4. When applicable painting per John Deere JDM F17 Enterprise Specification for
Paint Performance

23. Allowable Heat Exchanger Aesthetics


23.1. Inherent to heat exchanger manufacturing are a number of visual attributes that may
present a negative perception of quality to the end user without affecting cooler
performance in any appreciable way.
23.1.1. Such visual attributes include but are not limited to:
23.1.1.1. Leak repair (weld, epoxy, silicone)
23.1.1.2. Brazing flux residues
23.1.1.3. Fin anomalies/damage
23.1.1.4. Tube deformation
23.1.1.5. Side sheet damage
23.1.1.6. Braze fixture witness marks
23.1.1.7. Welding anomalies

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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.

24. Handling Protection


24.1. Fitting threads (both internal and external) must be individually protected from nicks
and scratches detrimental to their function. All passages must be securely capped or
plugged to prevent entrance of dirt or other contaminants prior to assembly and for
parts distribution handling and storage. Paper caps and plugs are not permitted.
24.2. Protection must meet the following criteria:
24.2.1. Must be easily removable without damaging sealing surfaces.
24.2.2. Must remain effective during standard handling procedures.
24.2.3. Must be such that it cannot be forced into the ID by hand.
24.2.4. Must be such that it has to be removed in order to allow the installation
in the intended assembly.

25. References
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25.1. Industry standards


25.1.1. ASTM G 85 Sea Water Acidified Accelerated Test
25.1.2. ASTM D6210 Standard Specification for Fully-Formulated Glycol Base
Engine Coolant for Heavy-Duty Engines
25.1.3. ASTM D975 Standard Specification for Diesel Fuel Oils
25.1.4. ASTM D1141 Standard Practice for the Preparation of Substitute
Ocean Water
25.1.5. ASTM D6751 Standard Specification for Biodiesel Fuel Blend Stock
(B100) for Middle Distillate Fuels
25.1.6. EN 590 Automotive fuels Diesel - Requirements and test methods
25.1.7. EN14214 Liquid petroleum products Fatty acid methyl esters (FAME)
for use in diesel engines and heating applications - Requirements and test
methods
25.1.8. ISO 261 General purpose metric screw threads -- General plan
25.1.9. ISO 3457 Earth-Moving Machinery Guards - Definitions and
Requirements
25.1.10. SAE AS5131 Tube End - Beaded, Design Standard
25.1.11. SAE J20 Coolant System Hoses
25.1.12. SAE J1927 Cumulative Damage Analysis For Hydraulic Hose
Assemblies
25.1.13. SAE J1231 Formed Tube Ends for Hose Connections and Hose
Fittings
25.2. John Deere standards approved for supplier distribution
25.2.1. John Deere DTW 1046 Tube and Hose Fittings Air Conditioning
Refrigerant
25.2.2. John Deere DTW 1223 Radiator and Heater Hose Specification
25.2.3. John Deere JDM F17 Enterprise Specification for Paint Performance
25.2.4. John Deere JDM J12 Diesel Fuel Specification
25.2.5. John Deere JDM J20 Specification for Anti-Brake Chatter
Transmission/Hydraulic Fluids
25.2.6. John Deere JDQ 64 Cleanliness of Parts and Components
Determination of Particulate Contamination — Gravimetric Method
CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 52 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

25.2.7. John Deere JDS-G 135 Worldwide Recommendations for Fuels,


Coolants, and Lubricants for John Deere Equipment
25.2.8. John Deere JDS G169 Cleanliness Classifications of Parts,
Assemblies and Fluids
25.2.9. John Deere JDS-G223 Supplier Quality Manual – Program
Requirements
25.2.10. John Deere JDS-G226 Cleanliness Requirements for Air Conditioning
Hose and Tube Assemblies, Evaporator Cores, and Condenser Cores
25.2.11. John Deere JDS G242.4 Recommended Cleanliness Classification
System and Internal Cleanliness Levels for Air-Cooled and Liquid-Cooled Heat
Exchangers
25.2.12. John Deere JDV 20.1 Specification for Arc Welding
25.3. John Deere Guidelines, standards and procedures not approved for supplier
distribution
25.3.1. John Deere DGL-TX-0500_Cooling_Design_Guideline (located in eKV)
25.3.2. John Deere DTW 2378 C&F Engine Application Requirements and
Guidelines
25.3.3. For John Deere internal use only see DTW 2807 Component Durability
Goals Technical Specification for All Products
25.3.4. John Deere DTW 3529 Structure Durability Goals Technical
Specification for All Products
25.3.5. John Deere EAP 0501-002 Cooling System Performance and
Underhood Temperature Testing
25.3.6. John Deere EAP 0501-004 Airflow Development Facility
25.3.7. John Deere EAP 0501-006 Heat Exchanger Pressure Cycle Durability
25.3.8. John Deere EAP 0501-008 Thermal Cycle Durability of Heat
Exchangers
25.3.9. John Deere EAP 0400-011 Engine Cooling System Application
Approval Testing
25.3.10. John Deere EAP 9009-004 Cooling Package Power Wash Test
Procedure
25.3.11. John Deere Power Systems Engine Application Requirements

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 53 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

25.3.12. John Deere RGS 50012 Specification for Cool-Gard™ II Factory-Fill


and Service-Fill Engine Coolants

26. Appendix A: Reference material on erosion/corrosion


*Tube side velocity should be less than 2.7m/s.
** Corrosion and erosion of aluminum radiator depends on:
 Material properties
 Coolant corrosion inhibitor formulation
 Hydrodynamic forces due to coolant flow
 Water/Glycol concentration
If the wall shear stress created by the flowing coolant becomes too great, the protection
silicate and the oxide layer can be eroded. Leaving unprotected metal ions that can react
with the coolant. At Reynolds Number greater than 104, the flow will be full developed
turbulent flow. Momentum from the free stream will be transfer into the boundary layer
increasing its velocity and the wall shear stress. Flow in this regime should be avoided.
At transitional flow rates 2300< Re < 104, smaller scale turbulent eddies will exist with the
flow. These small scale effects will be random expect when a surface discontinuity, such
as tube weld creates a regular local phenomenon. This may load to localized erosion and
corrosion.
Even at laminar flow rates Re<2300, some erosion may still occur in the entrance to the
tubes where the flow regime is still developing. Irregularly shaped tube ends and burrs from
tube cut-off can trigger local disturbances that can increase tube damage.
In areas of excessive flow rates (hydrodynamic forces) there may be erosion corrosion
which produces broad shallow regions of thinning quite unlike corrosion pits. ASTM 2570.

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

27. Appendix B Performance Characteristics


CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-07-27 VERSION: JD90 54 of 55
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3806
744/824L Cooling System Performance Specification

See DVP&R for heat transfer, internal pressure drop and external pressure drop for each
heat exchanger.

CHANGE DOCUMENT: AD5778YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-07-27 VERSION: JD90 55 of 55

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