ASTM D7583-16(2023)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D7583 − 16 (Reapproved 2023)
Standard Test Method for
John Deere Coolant Cavitation Test
This standard is issued under the fixed designation D7583; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope
External Oil System 6.2.7.3
Oil Sample Valve Location 6.2.7.4
1.1 This test method is commonly referred to as the John
Unacceptable Oil System Materials 6.2.7.5
Deere Cavitation Test. The test method defines a heavy-duty Crankcase Aspiration 6.3
Blowby Rate 6.4
diesel engine to evaluate coolant protection as related to
System Time Responses 6.5
cylinder liner pitting caused by cavitation.
Clearance Measurements 6.6
Engine and Cleaning Fluids 7
1.2 The values stated in SI units are to be regarded as the
Engine Oil 7.1
standard. The values given in parentheses are for information
Test Fuel 7.2
Test Coolant 7.3
only. The only exception is where there is no direct SI
Solvent 7.4
equivalent such as screw threads, national pipe threads/
Preparation of Apparatus 8
diameters, and tubing sizes.
Cleaning of Parts 8.1
General 8.1.1
1.3 This standard does not purport to address all of the
Engine Block 8.1.2
safety concerns, if any, associated with its use. It is the
Cylinder Head 8.1.3
Rocker Cover and Oil Pan 8.1.4
responsibility of the user of this standard to establish appro-
External Oil System 8.1.5
priate safety, health, and environmental practices and deter-
Rod Bearing Cleaning and Measurement 8.1.6
mine the applicability of regulatory limitations prior to use. Ring Cleaning and Measurement 8.1.7
Injector Nozzle 8.1.8
See Annex A1 for general safety precautions.
Pistons 8.1.9
1.4 Table of Contents:
Engine Assembly 8.2
General 8.2.1
Scope 1
Parts Reuse and Replacement 8.2.2
Referenced Documents 2
Build-Up Oil 8.2.3
Terminology 3
Coolant Thermostat 8.2.4
Summary of Test Method 4
Fuel Injectors 8.2.5
Significance and Use 5
New Parts 8.2.6
Apparatus 6
Operational Measurements 8.3
Test Engine Configuration 6.1
Units and Formats 8.3.1
Test Engine 6.1.1
Instrumentation Calibration 8.3.2
Test Stand Configuration 6.2
Fuel Consumption Rate Measurement Calibration 8.3.2.1
Engine Mounting 6.2.1
Temperature Measurement Calibration 8.3.2.2
Intake Air System 6.2.2
Pressure Measurement Calibration 8.3.2.3
Aftercooler 6.2.3
Temperatures 8.3.3
Exhaust System 6.2.4
Measurement Location 8.3.3.1
Fuel System 6.2.5
Coolant Out Temperature 8.3.3.2
Coolant System 6.2.6
Coolant In Temperature 8.3.3.3
Oil System 6.2.7
Fuel In Temperature 8.3.3.4
Oil Volume 6.2.7.1
Oil Gallery Temperature 8.3.3.5
Pressurized Oil Fill System 6.2.7.2
Intake Air Temperature 8.3.3.6
Intake Air after Compressor Temperature 8.3.3.7
Intake Manifold Temperature 8.3.3.8
This test method is under the jurisdiction of ASTM Committee D15 on Engine
Exhaust Temperature 8.3.3.9
Coolants and Related Fluids and is the direct responsibility of Subcommittee D15.11
Exhaust after Turbo Temperature 8.3.3.10
on Heavy Duty Coolants.
Additional Temperatures 8.3.3.11
Current edition approved Sept. 1, 2023. Published September 2023. Originally
Pressures 8.3.4
approved in 2009. Last previous edition approved in 2016 as D7583 – 16. DOI:
Measurement Location and Equipment 8.3.4.1
10.1520/D7583-16R23.
Condensation Trap 8.3.4.2
American Society for Testing and Materials takes no position respecting the
Coolant Pressure 8.3.4.3
validity of any patent rights asserted in connection with any item mentioned in this Fuel Pressure 8.3.4.4
standard. Users of this standard are expressly advised that determination of the Oil Gallery Pressure 8.3.4.5
Intake Air Pressure 8.3.4.6
validity of any such patent rights, and the risk of infringement of such rights, are
entirely their own responsibility.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D7583 − 16 (2023)
Intake Air after Compressor Pressure 8.3.4.7 Precision 13.1
Intake Manifold Pressure 8.3.4.8 Intermediate Precision Conditions 13.1.1
Exhaust after Turbo Pressure 8.3.4.9 Intermediate Precision Limit 13.1.2
Crankcase Pressure 8.3.4.10 Reproducibility Conditions 13.2
Additional Pressures 8.3.4.11 Reproducibility Limit 13.2.1
Flow Rates 8.3.5 Bias 13.3
Flow Rate Location and Measurement Equipment 8.3.5.1 Keywords 14
Blowby 8.3.5.2 Annexes
Fuel Flow 8.3.5.3 Safety Precautions Annex A1
Engine/Stand Calibration and Non-Reference Coolant 9 Intake Air Aftercooler Annex A2
Tests Engine Build Parts Kit Annex A3
General 9.1
Sensor Locations, Special Hardware, and Engine Block Annex A4
New Test Stand 9.2 Modifications
New Test Stand Calibration 9.2.1 Fuel Specifications Annex A5
Stand Calibration Period 9.3 John Deere Service Publications Annex A6
Stand Modification and Calibration Status 9.4 Specified Units and Formats Annex A7
Test Numbering System 9.5 Report Forms and Data Dictionary Annex A8
General 9.5.1 Coolant Analysis Annex A9
Reference Coolant Tests 9.5.2 Oil Analysis Annex A10
Non-Reference Coolant Tests 9.5.3 Determination of Operational Validity Annex A11
Reference Coolant Test Acceptance 9.6 Typical System Configurations Appendix X1
Reference Coolant Accountability 9.7
1.5 This international standard was developed in accor-
Last Start Date 9.8
dance with internationally recognized principles on standard-
Donated Reference Coolant Test Programs 9.9
Adjustments to Reference Coolant Calibration Periods 9.10
ization established in the Decision on Principles for the
Procedure Development 9.10.1
Development of International Standards, Guides and Recom-
Parts and Fuel Shortages 9.10.2
mendations issued by the World Trade Organization Technical
Reference Coolant Test Data Flow 9.10.3
Special Use of The Reference Coolant Calibration System 9.10.4
Barriers to Trade (TBT) Committee.
Procedure 10
Engine Installation and Stand Connections 10.1
2. Referenced Documents
Break-in 10.2
Coolant System Fill for Break-in 10.2.1
2.1 ASTM Standards:
Oil Fill for Break-in 10.2.2
D86 Test Method for Distillation of Petroleum Products and
Engine Build Committed 10.2.3
Liquid Fuels at Atmospheric Pressure
Break-in Conditions 10.2.4
Shutdown during Break-in 10.2.5
D93 Test Methods for Flash Point by Pensky-Martens
250-Hour Test Procedure 10.3
Closed Cup Tester
Coolant System Fill for Test 10.3.1
Zero-Hour Coolant Sample 10.3.1.1 D97 Test Method for Pour Point of Petroleum Products
Oil Fill for Test 10.3.2
D130 Test Method for Corrosiveness to Copper from Petro-
Zero-Hour Oil Sample 10.3.2.1
leum Products by Copper Strip Test
Warm-Up 10.3.3
Warm-up Conditions 10.3.3.1 D235 Specification for Mineral Spirits (Petroleum Spirits)
Shutdown during Warm-up 10.3.3.2
(Hydrocarbon Dry Cleaning Solvent)
20-Hour Steady State Extended Break-in 10.3.4
D287 Test Method for API Gravity of Crude Petroleum and
20-Hour Steady State Extended Break-in Conditions 10.3.4.1
Shutdown during 20-Hour Extended Break-in 10.3.4.2 Petroleum Products (Hydrometer/Method)
230-Hour Cyclic 10.4
D445 Test Method for Kinematic Viscosity of Transparent
230-Hour Cyclic Conditions 10.4.1
and Opaque Liquids (and Calculation of Dynamic Viscos-
Shutdown during 230-Hour Cyclic 10.4.2
Shutdown and Maintenance 10.5 ity)
Normal Shutdown 10.5.1
D482 Test Method for Ash from Petroleum Products
Emergency Shutdown 10.5.2
D524 Test Method for Ramsbottom Carbon Residue of
Maintenance 10.5.3
Downtime 10.5.4 Petroleum Products
Operating conditions 10.6
D613 Test Method for Cetane Number of Diesel Fuel Oil
Stage Transition Times 10.6.1
D664 Test Method for Acid Number of Petroleum Products
Test Timer 10.6.2
Operational Data Acquisition 10.6.3
by Potentiometric Titration
Operational Data Reporting 10.6.4
D976 Test Method for Calculated Cetane Index of Distillate
Coolant Sampling 10.6.5
Fuels
Oil Sampling 10.6.6
End of Test (EOT) 10.7 D1121 Test Method for Reserve Alkalinity of Engine Cool-
Shutdown 10.7.1
ants and Antirusts
Oil Drain 10.7.2
D1177 Test Method for Freezing Point of Aqueous Engine
Coolant Drain 10.7.3
Engine Disassembly 10.7.4
Coolants
Calculations, Ratings and Test Validity 11
D1287 Test Method for pH of Engine Coolants and Antirusts
Liner Pit Count 11.1
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
Coolant Analysis 11.2
Oil Analyses 11.3
leum Products by Fluorescent Indicator Adsorption
Assessment of Operational Validity 11.4
Report 12
Report Forms 12.1
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Reference Coolant Test 12.2
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Electronic Transmission of Test Results 12.3
Standards volume information, refer to the standard’s Document Summary page on
Precision and Bias 13
the ASTM website.
D7583 − 16 (2023)
D2274 Test Method for Oxidation Stability of Distillate Fuel 3.1.7 non-standard test, n—a test that is not conducted in
Oil (Accelerated Method) conformance with the requirements in the standard test
D2500 Test Method for Cloud Point of Petroleum Products method; such as running in an non-calibrated test stand or
and Liquid Fuels using different test equipment, applying different equipment
D2622 Test Method for Sulfur in Petroleum Products by assembly procedures, or using modified operating conditions.
Wavelength Dispersive X-ray Fluorescence Spectrometry D5844
D2709 Test Method for Water and Sediment in Middle
3.1.8 reference coolant, n—a coolant of known performance
Distillate Fuels by Centrifuge
characteristics, used as a basis for comparison.
D4052 Test Method for Density, Relative Density, and API
3.1.9 test coolant, n—any coolant subjected to evaluation in
Gravity of Liquids by Digital Density Meter
an established procedure.
D4485 Specification for Performance of Active API Service
3.1.10 wear, n—the loss of material from, or relocation of
Category Engine Oils
material on, a surface.
D4737 Test Method for Calculated Cetane Index by Four
3.1.10.1 Discussion—Wear generally occurs between two
Variable Equation
surfaces moving relative to each other, and is the result of
D5185 Test Method for Multielement Determination of
Used and Unused Lubricating Oils and Base Oils by mechanical or chemical action or by a combination of me-
chanical and chemical actions. D5302
Inductively Coupled Plasma Atomic Emission Spectrom-
etry (ICP-AES)
3.2 Definitions of Terms Specific to This Standard:
D5302 Test Method for Evaluation of Automotive Engine
3.2.1 cylinder liner, n—in internal combustion engines, the
Oils for Inhibition of Deposit Formation and Wear in a
replaceable cylinders in which the pistons move up and down
Spark-Ignition Internal Combustion Engine Fueled with
and combustion takes place.
Gasoline and Operated Under Low-Temperature, Light-
4 3.2.2 overhead, n—in internal combustion engines, the
Duty Conditions (Withdrawn 2003)
components of the valve train located in or above the cylinder
D5844 Test Method for Evaluation of Automotive Engine
head.
Oils for Inhibition of Rusting (Sequence IID) (Withdrawn
2003) 3.2.3 valve train, n—in internal combustion engines, the
series of components, such as valves, crossheads, rocker arms,
D5967 Test Method for Evaluation of Diesel Engine Oils in
T-8 Diesel Engine push rods and camshaft, that open and close the intake and
exhaust valves.
E29 Practice for Using Significant Digits in Test Data to
Determine Conformance with Specifications
E202 Test Methods for Analysis of Ethylene Glycols and 4. Summary of Test Method
Propylene Glycols
4.1 This test engine is a John Deere six-cylinder 10.1 L
E344 Terminology Relating to Thermometry and Hydrom-
(6101H). Test operation includes a 19 min engine break-in, a
etry
20 h coolant break-in, and 230 h in five cyclic steps.
3. Terminology
4.2 Prior to each test, the engine is cleaned and assembled
with new cylinder liners and gaskets.
3.1 Definitions:
3.1.1 blind reference coolant, n—a reference coolant, the
4.3 The test stand is equipped with the appropriate instru-
identity of which is unknown by the test facility.
mentation to control engine speed, fuel flow, and other oper-
ating parameters.
3.1.2 blowby, n—in internal combustion engines, the com-
bustion products and unburned air-and-fuel mixture that enter
4.4 Coolant performance is characterized by determining
the crankcase. D5302
the total liner pit count area.
3.1.3 calibrate, v—to determine the indication or output of a
measuring device with respect to that of a standard. E344 5. Significance and Use
3.1.4 heavy-duty, adj—in internal combustion engine
5.1 This test method was developed to evaluate the ability
operation, characterized by average speed, power output, and
of a heavy-duty diesel engine coolant to provide protection
internal temperatures that are close to the potential maximum.
against damage resulting from a phenomenon known as
D4485
cylinder liner cavitation corrosion.
3.1.5 heavy-duty engine, n—in internal combustion engines,
5.2 This test method may be used for engine coolant
one that is designed to allow operation continuously at or close
specification acceptance when all details of this test method are
to its peak output. D4485
in compliance.
3.1.6 non-reference coolant, n—any coolant other than a
5.3 The design of the engine used in this test method is a
reference coolant, such as a research formulation, commercial
production OEM diesel engine modified to consistently pro-
coolant or candidate coolant. D5844
duce the operating conditions that accelerate damage from
cylinder liner cavitation. This factor, along with the accelerated
operating conditions needs to be considered when extrapolat-
The last approved version of this historical standard is referenced on
www.astm.org. ing test results.
D7583 − 16 (2023)
6. Apparatus 6.2.7.1 Oil Volume—Although the system volume is not
specified, an excessively large volume may increase the time
6.1 Test Engine Configuration:
required for the engine fluid temperatures to attain specifica-
6.1.1 Test Engine—The John Deere 6101H is an inline
tion. A system volume of 50.5 L or less, including the volume
six-cylinder heavy duty diesel engine with 10.1 L of displace-
contained in the engine, has proven satisfactory.
ment and is turbocharged and aftercooled. The engine has an
6.2.7.2 Pressurized Oil Fill System—The oil fill system is
overhead valve configuration. It features mechanical control of
not specified. A typical configuration includes an electric
fuel metering and fuel injection timing.
pump, a 50 L reservoir, and a transfer hose. The location for the
6.1.2 Oil Pan Modification—Modify the oil pan as shown in
pressurized fill is located on the filter head (Fig. A4.12).
Fig. A4.9.
6.2.7.3 External Oil System—Configure the external oil
6.2 Test Stand Configuration:
system according to Fig. A4.12. Use a 10 L to 13 L container
6.2.1 Engine Mounting—Install the engine so that it is
for the external oil reservoir. Use Viking Pump model number
upright and the crankshaft is horizontal.
SG053514. Nominal pump motor speed is 1725 r/min.
6.2.1.1 The engine mounting hardware should be configured
6.2.7.4 Oil Sample Valve Location—Locate the oil sample
to minimize block distortion when the engine is fastened to the
valve on the return line from the external oil system to the
mounts. Excessive block distortion may influence test results.
engine. Locate the valve as close to the return pump as possible
6.2.2 Intake Air System—With the exception of the intake
(Fig. A4.11).
air tube, the intake air system is not specified. A typical
6.2.7.5 Unacceptable Oil System Materials—Brass or cop-
configuration is shown in Fig. X1.1. The air filter should be
per fittings can influence used oil wear metals analyses and
typical of air filters used for engines in heavy-duty applica-
shall not be used in the external oil system.
tions. Install the intake air tube (Fig. A4.2) near the intake of
the turbocharger compressor. The system shall allow control of
6.3 Crankcase Aspiration—Vent the blowby gas at the port
applicable parameters listed in Table 1 and Table 2.
located on the left side of the valve cover (Fig. A4.10). Route
6.2.3 Aftercooler—Use a Modine aftercooler. Instructions
the vent line downward from the valve cover port to the
for obtaining the correct aftercooler are listed in A2.1.
blowby canister. The line shall be between 1.2 m and 1.8 m in
length and minimum 15.9 mm inside diameter.
NOTE 1—Difficulty in achieving or maintaining intake manifold pres-
sure or intake manifold temperature, or both, may be indicative of
6.4 Blowby Rate—The flow rate measurement device is not
insufficient or excessive restriction.
specified. The blowby canister shall be a minimum of 35 L in
6.2.4 Exhaust System—Install the exhaust tube (Fig. A4.7)
volume. The outlet of the blowby canister to the flow rate
near the discharge flange of the turbocharger turbine housing.
device shall be a minimum of 31.8 mm inside diameter. The
The piping downstream of the exhaust tube is not specified. A
hose connecting the blowby canister to the flowrate device
method to control exhaust pressure is required.
shall be a minimum of 38.1 mm inside diameter. The length of
6.2.5 Fuel System—The fuel supply and filtration system is
this hose is not specified.
not specified. A typical configuration is shown in Fig. X1.2.
6.5 System Time Responses—The maximum allowable sys-
The fuel consumption rate is determined by measuring the rate
tem time responses are shown in Table 3.
of fuel flowing into the day tank. A method to control the fuel
temperature is required.
6.6 Clearance Measurements—Piston skirt outside diameter
6.2.6 Coolant System—The system configuration is not
and liner inside diameter, piston pin, rod and main bearings.
specified. A typical configuration consists of a non-ferrous core
6.6.1 Piston Skirt—Measure and record the piston skirt
heat exchanger, a reservoir (expansion tank), a temperature
outside diameter.
control valve, and a vent line from the coolant vent block on
Spec = 130.04–130.05 mm, max
the engine to the bottom of the expansion tank as shown in Fig.
X1.3. This is a non-pressurized system. The system should 6.6.2 Main Bearings—Inspect the crankshaft main bearings
have a sight glass to detect air entrapment. for condition and clearance. The crankshaft will have to be
6.2.7 Oil System: supported to perform the plastigage clearance check.
A
TABLE 1 230-Hour Test Sequence Controlled Conditions
Stage
Parameter Unit
Low Idle Peak Torque Full Load Over Speed Fast Idle
Stage Length min 1.5 1 4 1 0.5
Speed r/min 900 ± 5 1500 ± 5 2100 ± 5 2300 ± 5 2500 ± 5
Power kW record record record record record
A
Torque (typical) N·m 0 ± 5 1680 ± 10 1220 ± 10 1080 ± 10 0 ± 5
A
Intake Manifold Temperature °C 93 ± 5 100 ± 5 100 ± 5 100 ± 5 100 ± 5
A
Coolant Out Temperature °C 70 ± 2 70 ± 2 70 ± 2 70 ± 2 70 ± 2
Fuel In Temperature °C 40 ± 2 40 ± 2 40 ± 2 40 ± 2 40 ± 2
A
Turbo Compressor Inlet Temperature °C 30 ± 2 30 ± 2 30 ± 2 30 ± 2 30 ± 2
Exhaust Pressure kPa record record 5 ± 1 record record
A
Intended set point, but may vary due to cyclic conditions.
D7583 − 16 (2023)
TABLE 2 230-Hour Test Sequence Typical Conditions
Stage
Parameter Unit
Low Idle Peak Torque Full Load Over Speed Fast Idle
Fuel Flow Kg/h 0 ± 1 40 ± 1 68 ± 1 68 ± 1 45 ± 1
Blowby Flow l/min 85 ± 2 311 ± 2 311 ± 2 283 ± 2 141 ± 2
Coolant In Temperature °C 56 ± 2 66 ± 2 63 ± 2 61 ± 2 61 ± 2
Oil Gallery Temperature °C 82 ± 2 83 ± 2 89 ± 2 91 ± 2 90 ± 2
Intake Manifold Pressure kPa $1 $70 $70 $70 $55
Exhaust Temperature °C 260 ± 100 705 ± 100 760 ± 100 760 ± 100 427 ± 100
Fuel Pressure kPa record record record record record
Oil Gallery Pressure kPa record record record record record
Coolant Inlet Pressure kPa record record record record record
Coolant Outlet Pressure kPa record record record record record
Coolant System Pressure kPa open open open open open
Crankcase Pressure kPa record record record record record
Inlet Air Pressure kPa record record record record record
TABLE 3 Maximum Allowable System Time Responses TABLE 4 Cylinder Head Rebuild Specifications
Time Response Head Flatness 0.1016 mm entire length or width
Measurement
(s) Head Thickness 166.294 mm to 166.802 mm
Intake Valve Stem OD 9.462 mm to 9.487 mm
Speed 2.0
Exhaust Valve Stem OD 9.436 mm to 9.462 mm
Temperature 3.0
Valve Guide ID 9.512 mm to 9.538 mm
Pressure 3.0
Valve Guide Installed Height 36.170 mm to 39.167 mm
Flow 15.0
Intake Valve to Guide Clear 0.025 mm to 0.127 mm
Exhaust Valve to Guide 0.051 mm to 0.152 mm
Clear
Valve Seat Run Out 0.051 mm max
Intake Spring Tension 35.3802 kg to 40.82331 kg at
Closed 52.578 mm
Spec = 0.046–0.152 mm, max
Intake Spring Tension Open 82.55381 kg to 89.81129 kg at 38.1 mm
Exhaust Spring Tension 29.02991 kg to 34.47302 kg at
6.6.3 Rod Bearings—Inspect the crankshaft main bearings
Closed 54.61 mm
for condition and clearance. The crankshaft will have to be
Exhaust Spring Tension 81.19303 kg to 88.45051 kg at
Open 38.608 mm
supported to perform the plastigage clearance check.
Intake Valve Seat Angle 29.5 degrees to 30.5 degrees
Spec = 0.046–0.152 mm, max
Exhaust Valve Seat Angle 37 degrees to 38 degrees
Intake Valve Recession 2.692 mm to 3.327 mm
6.6.4 Cylinder Liners—Measure and record the cylinder
Exhaust Valve Recession 1.626 mm to 2.286 mm
liners inside diameter.
Intake Valve Lash 0.330 mm to 0.432 mm
Exhaust Valve Lash 0.584 mm to 0.686 mm
OEM liner ID spec = 130.165–130.175 mm
Intake Seat Width 1.600 mm to 2.997 mm
Test liner ID spec = Piston Skirt OD + 0.254 mm
Exhaust Seat Width 1.194 mm to 2.997 mm
Test liner OD spec = Block ID – 0.1016 mm
6.6.5 Piston Ring End Gap—Measure and record the piston
ring end gap and the oil control ring side clearance.
7.3 Engine Coolant—Use specified test coolant mixed with
Spec Top = 0.432–0.686 mm
deionized water.
2nd = 1.016–1.27 mm
Oil = 0.330–0.635 mm
7.4 Solvent—Use a solvent which meets Specification D235
OCSC = 0.061–0.102 mm
for mineral spirits, Type II, Class C for Aromatic Content
New Max Used = 0.165 cm
(0–2 % vol), Flash Point (142 °F / 61 °C, min), and Color (not
6.6.6 Piston Pin to Connecting Rod Bushing—Measure and
darker than +25 on Saybolt Scale or 25 on Pt-Co Scale).
record the piston pin to connecting rod bushing clearance.
Obtain a Certificate of Analysis for each batch of solvent from
Spec = 0.018–0.762 mm
the supplier. (Warning—Combustible. Health Hazard. Use
6.6.7 Connecting Rod Bearing Clearance—Install the pis-
adequate safety precautions with all solvents and cleaners.)
tons and connecting rods. Use plastigage to measure the
8. Preparation of Apparatus
connecting rod bearing clearance.
Spec = 0.051–0.127 mm 8.1 Cleaning of Parts:
8.1.1 General—The preparation of test engine components
6.6.8 Cylinder Head—Measure and record the cylinder head
specific to the John Deere Coolant Cavitation Test are indicated
specifications in accordance with Table 4.
in this section. Use the John Deere publication CTM61
(13MAY93) 6101 Component Technical Manual for prepara-
7. Engine and Cleaning Fluids
tion of other engine parts. Take precautions to prevent rusting
7.1 Engine Oil—Approximately 70 L of John Deere Plus 50
of iron components.
TY6391 is required to complete the test.
7.2 Test Fuel—Approximately 4500 gal of Off-Highway
Cleaning solvent that meets the requirements of 7.4 is available from local
diesel fuel is required to complete the test. Fuel property
petroleum products suppliers.
tolerances are shown in Annex A5. Available from http://www.deere.com.
D7583 − 16 (2023)
8.1.2 Engine Block—Disassemble the engine, including re- 8.2.1 General—Except as noted in this section, use the
moval of the pistons and cylinder liners. Thoroughly clean the procedures indicated in the John Deere CTM61 (13MAY93)
surfaces and oil passages (galleries). Removal of camshaft Component Technical Manual. Assemble the engine with new
bearings is at the discretion of the laboratory. liners and gaskets.
8.2.2 Parts Reuse and Replacement—Engine components
8.1.3 Cylinder Head—Disassemble and clean the cylinder
may be reused or replaced at the discretion of the laboratory,
head. Use a brush as necessary to remove deposits.
except as noted in 8.2.6.
8.1.4 Rocker Cover and Oil Pan—Clean the rocker cover
8.2.3 Build-Up Oil—Use John Deere Plus 50 SAE 15w-40.
and oil pan. Use a brush as necessary to remove deposits.
8.2.4 Coolant Thermostat—Lock the engine coolant ther-
8.1.5 External Oil System—Flush the internal surfaces of
mostat open.
the oil lines and the external reservoir with solvent. Repeat
8.2.5 Fuel Injectors—The fuel injectors may be reused.
until the solvent drains clean. Flush solvent through the oil
Dedicate the injectors to a particular cylinder.
pumps until the solvent drains clean.
8.2.6 New Parts—The only standard new parts are liners
8.1.6 Rod Bearing Cleaning and Measurement:
and gaskets.
8.1.6.1 Clean the rod bearings with Stoddard solvent. Use a
non-metallic soft bristle brush if necessary. Avoid handling the 8.3 Operational Measurements:
rod bearings with bare hands. Use gloves or plastic covered 8.3.1 Units and Formats—See Annex A7.
tongs.
8.3.2 Instrumentation Calibration:
8.3.2.1 Fuel Consumption Rate Measurement Calibration—
8.1.6.2 Spray the rod bearings with air until dry.
Calibrate the fuel consumption rate measurement system
8.1.6.3 Rinse the rod bearings in pentane and dry with air.
before every reference test sequence and at least once every
8.1.6.4 Perform the plastigage clearance check (0.051 cm to
twelve months. Temperature-compensate volumetric systems,
0.127 cm max).
and calibrate them against a mass flow device. The flow meter
8.1.7 Ring Cleaning and Measurement:
located on the test stand shall indicate within 0.2 % of the
8.1.7.1 After the piston rings have been removed from the
calibration standard. Trace the calibration standard to national
piston use carburetor cleaner or Stoddard solvent to soften the
standards.
carbon deposits. Once the deposits have softened use a hand
8.3.2.2 Temperature Measurement Calibration—Calibrate
held brass wire brush or a brass pick to remove the carbon
the temperature measurement systems before every reference
deposits. Scotch-Brite (3M part number 7440) may also be
test sequence and at least once every twelve months. Each
used to help remove carbon deposits. Once the piston rings
temperature measurement system shall indicate within
have had all of the carbon removed spray them down with
60.5° C of the laboratory calibration standard. Trace the
Stoddard solvent and dry them with compressed air. Place the
calibration standard to national standards.
piston rings in clean numbered bags for later measurement and
8.3.2.3 Pressure Measurement Calibration—Calibrate the
installation on the pistons. Avoid handling the rings with bare
pressure measurement systems before every reference test
hands. Use gloves or plastic covered tongs.
sequence and at least once every 12 months. Trace the
8.1.8 Injector Nozzle:
calibration standard to national standards.
8.1.8.1 Verify nozzle retaining nut torque is tightened to
8.3.3 Temperatures:
88 N·m.
8.3.3.1 Measurement Location—The temperature measure-
8.1.8.2 Test nozzle for opening pressure, leakage, chatter,
ment locations are specified in this section. The measurement
and spray pattern per the CTM61 component technical manual.
equipment is not specified. Install the sensors such that the tip
8.1.9 Pistons—Care must be taken in cleaning the pistons in
is located midstream of the flow unless otherwise indicated.
order to prolong life.
The accuracy and resolution of the temperature measurement
sensors and the complete measurement system shall follow the
8.1.9.1 After the pistons have been removed from the
connecting rods remove loose carbon and oil by washing the guidelines detailed in ASTM Research Report RR:D02-1218.
pistons in hot soapy water or Stoddard solvent. 8.3.3.2 Coolant Out Temperature—Install the sensor in a
⁄4 in. NPT hole at the top of the coolant out tube (Fig. A4.4).
8.1.9.2 Carefully remove the piston rings with ring pliers
8.3.3.3 Coolant In Temperature—Install the sensor located
and place them in numbered plastic bags.
on the right side of the coolant pump intake housing in a ⁄4 in.
8.1.9.3 Soak the pistons in carburetor cleaner until the
NPT hole (Fig. A4.3).
carbon deposits are softened, then wash the pistons in hot
8.3.3.4 Fuel In Temperature—Install the sensor in a ⁄4 in.
soapy water to neutralize the carburetor cleaner.
NPT hole located on the side of the injector pump (Fig. A4.5).
8.1.9.4 Remove any remaining carbon deposits with a hand
8.3.3.5 Oil Gallery Temperature—Install the sensor in a
held brass wire brush or a brass pick.
⁄4 in. NPT hole located at the right rear of the engine (Fig.
8.1.9.5 When all of the carbon deposits have been removed
A4.8).
from the pistons spray them down with solvent and dry them
with compressed air.
8.1.9.6 Place the pistons in clean numbered bags for later
Supporting data have been filed at ASTM International Headquarters and may
measurement and installation.
be obtained by requesting Research Report RR:D02-1218. Contact ASTM Customer
8.2 Engine Assembly: Service at service@astm.org.
D7583 − 16 (2023)
8.3.3.6 Intake Air Temperature—Install the sensor in a ⁄4 in. measurement system shall follow the guidelines detailed in
NPT hole located approximately 26 in. from the compressor ASTM Research Report RR:D02-1218.
inlet (Fig. A4.2). 8.3.5.2 Blowby—The device used to measure the blowby
flow rate is not specified. See 6.4 for blowby measurement
8.3.3.7 Intake Air after Compressor Temperature—Install
system configuration details.
the sensor in a ⁄4 in. NPT hole located approximately 24 in.
8.3.5.3 Fuel Flow—The fuel consumption rate is deter-
from the compressor outlet (Fig. A4.1).
mined by measuring the fuel flowing to the day tank (Fig.
8.3.3.8 Intake Manifold Temperature—Install the sensor in a
X1.2).
⁄4 in. NPT hole located approximately 24 in. from the modine
outlet (Fig. A4.1).
9. Engine/Stand Calibration and Non-Reference Oil Tests
8.3.3.9 Exhaust Temperature—Install the sensors on the
9.1 General—Calibrate the test stand by conducting a test
center flange of the exhaust manifold as per Fig. A4.6.
with the designated reference coolant. Submit the results to the
8.3.3.10 Exhaust after Turbo Temperature—Install the sen-
1 ASTM Test Monitoring Center (TMC) for determination of
sor in a ⁄4 in. NPT hole located approximately 48 in. from the
acceptance according to the Lubricant Test Monitoring System
turbo outlet (Fig. A4.7).
(LTMS).
8.3.3.11 Additional Temperatures—Monitor any additional
temperatures considered to be beneficial.
9.2 New Test Stand—A new test stand is defined as a test
8.3.4 Pressures: stand that has never been calibrated.
9.2.1 New Test Stand Calibration—New stand calibration is
8.3.4.1 Measurement Location and Equipment—The pres-
determined according to the LTMS.
sure measurement locations are specified in this section. The
measurement equipment is not specified. The accuracy and
9.3 Stand Calibration Period—The calibration period is 12
resolution of the pressure measurement sensors and the com-
months for all calibration periods. Up to 12 operationally valid,
plete measurement system shall follow the guidelines detailed
non-reference coolant tests may be completed during each
in ASTM Research Report RR:D02-1218.
calibration period.
8.3.4.2 Condensation Trap—A condensation trap should be
9.3.1 The TMC may schedule more frequent reference
installed at the lowest elevation of the tubing between the
coolant tests or extend the calibration period.
pressure measurement location and the final pressure sensor for
9.4 Stand Modification and Calibration Status—Stand cali-
Crankcase Pressure, Intake Air Pressure, and Exhaust Pressure.
bration status may be invalidated by conducting any non-
Route the tubing to avoid intermediate loops or low spots
standard test or modification of the test and control systems or
before and after the condensation trap.
both. A non-standard test includes any test conducted under a
8.3.4.3 Coolant Pressure—Tank is open to atmosphere.
modified procedure, non-procedural hardware, controller set-
8.3.4.4 Fuel Pressure—Measure the pressure at the ⁄4 in.
point modifications, or any combination thereof. The TMC
NPT hole located on the side of the injector pump (Fig. A4.5).
should be contacted prior to any changes to determine the
8.3.4.5 Oil Gallery Pressure—Measure the pressure at the
effect on the calibration status.
⁄4 in. NPT hole located at the right rear of the engine (Fig.
9.5 Test Numbering System:
A4.8).
9.5.1 General—The test number has three parts, W-X-Y-Z.
8.3.4.6 Intake Air Pressure—Measure the pressure at the
W represents the test stand number, X represents the stand run
⁄4 in.
...