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 3769
444-544L Cooling System 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 Initial Release AG0697YT 1DEC16 T. Kennedy
B Updates from PV&V Test Results 527867YT 4APR17 T. Kennedy

CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-04-04 VERSION: JD90 1 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System 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 32
10. Vehicle composite for Thermal and Pressure Cycle Fatigue Life Calculations 33
11. Thermal Cycle Test 33
12. Pressure Drop Test (internal fluid) 38
13. Burst Test 39
14. Pressure Cycle Tests 40
15. Shock/ Vibration Tests 44
16. External Corrosion 45
17. Internal Erosion Corrosion for Radiators 46
18. Cleaning Requirements for External Fouling 46
19. In Vehicle Customer Reparability Requirements 46
20. End of Line (EOL) 46
21. Cleanliness Requirements 47
22. Manufacturing Quality Requirements 47
23. Allowable Heat Exchanger Aesthetics 48
24. Handling Protection 49
25. References 49
26. Appendix A: Reference material on erosion/corrosion 51
27. Appendix B Performance Characteristics 52

CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-04-04 VERSION: JD90 2 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

Table of Figures
Figure 1 Cooling System Layout (544L) ............................................................................ 16
Figure 2 Envelop Dimensions ........................................................................................... 17
Figure 3 Cooling Package Airflow Layout (544L Pictured) ................................................ 19
Figure 4 Steady state pre-heats for Zone 1 (TOC)............................................................ 19
Figure 5 Steady state pre-heats for Zone 2 (RAD/HOC) .................................................... 20
Figure 6 Steady state pre-heats for Zone 3 (Condenser/fuel cooler stacked) .................... 20
Figure 7 Steady state pre-heats for Zone 4 (CAC) ............................................................. 20
Figure 8 Fan control software logic .................................................................................... 21
Figure 9 Expected Coolant Flows, Minimum Water Pump Inlet Pressures and Maximum
Radiator Pressure Drops .................................................................................................... 21
Figure 10 Engine Coolant Heat Rejection ......................................................................... 23
Figure 11 Typical Coolant System Layout .......................................................................... 24
Figure 12 CAC Heat Rejection CAC System and CAC Pressure Drop Requirements ....... 25
Figure 13 Typical CAC System Layout ............................................................................. 26
Figure 14 Typical TOC System Layout ............................................................................. 28
Figure 15 Typical Hydraulic System Layout ...................................................................... 29
Figure 16 Typical Axle System Layout .............................................................................. 31
Figure 17 Surge Tank Vent and Return Schematic ............................................................ 32

CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-04-04 VERSION: JD90 3 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System 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%

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DATE: 2017-04-04 VERSION: JD90 4 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System 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.
2.3. The supplier shall provide Deere with cooler performance information for use in
cooling system analysis. When appropriate, the supplier is 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 is 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
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.
CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-04-04 VERSION: JD90 5 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

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 is 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 is to provide guidance on strain gage locations. Deere will
install the strain gages.
2.6.8.1.2. Supplier is 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
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
CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-04-04 VERSION: JD90 6 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

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.
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.

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DATE: 2017-04-04 VERSION: JD90 7 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

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 following document pertains to the cooling systems for the FT4 models
of Deere 444L, 524L, and 544L 4WD Loaders manufactured in Davenport,
IA. These machines will be implemented in two phases: Phase 1 will
implement 524L and 544L (along with 624L), Phase 2 will implement 444L
(along with 644L and 724L). The scope of this program centers on an
updated cab and loader linkage. Cooling system changes from the K-Series
FT4 cooling systems to the L-Series FT4 cooling systems are limited to
metrification of ports and hexes on plumbing where possible. This cooling
system includes heat exchangers for the following vehicle systems:
 Engine
o Radiator
o Charge Air Cooler
o Fuel Cooler
 Hydraulics
 Transmission
 Axles (Front and Rear, independently)
 Air Conditioning Condenser
The coolers in this system will be arranged in the Quad-Cool™ format in the
aft-most portion of the machine. Heat exchangers will be stationary in relation
to the cooling plenum with the exception of the axle oil coolers which will be
affixed to the fan door. The fan door will pivot about one edge of the rear
opening of the cooling plenum and will contain a hydraulically driven sucker
fan with an optional reversing function. The supplier(s) will be responsible for
the design of individual heat exchangers or combination coolers, where
applicable. Deere will integrate individual heat exchangers into the cooling
system through the design of supporting structures, cooling airflow and fans,
CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-04-04 VERSION: JD90 8 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

plumbing and all other components not explicitly stated to be within the
design control of the supplier(s).The supplier may be requested to provide
mounting provisions for some Deere assembled components (i.e. hose and
wire harness mounting points).

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, Axle Oil Coolers, Hydraulic Oil Cooler, and Condenser)
must be permanently identified with the following data:
CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-04-04 VERSION: JD90 9 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System 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

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DATE: 2017-04-04 VERSION: JD90 10 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System 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
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
ArcticTM 22, oils meeting minimum API Service classification CI-4, Anti-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.

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DATE: 2017-04-04 VERSION: JD90 11 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System 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 251959 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
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SPECIFICATION
DTW 3769
444-544L Cooling System 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:
8.1.5.1. Stockpiling / Truck Loading 35%
8.1.5.2. Transport / Load & Carry 30%
8.1.5.3. Misc. (Excavate, Backdrag, Grade, etc.) 20%
8.1.5.4. Idle 15%
8.2. Engine – 444L
8.2.1. Model: FT4 4.5L PSS
8.2.2. Rated speed: 2200 rpm
8.2.3. Rated Power: 92kW
8.2.4. Peak torque speed: 1600 rpm
8.3. Engine – 524/544L
8.3.1. Model: FT4 6.8L PVS
8.3.2. Rated speed: 2200 rpm
8.3.3. Rated Power: 117.5 kW
8.3.4. Peak torque speed: 1500 rpm
8.4. Fan
8.4.1. Diameter: 698.5 mm
8.4.2. # of blades: 9
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.

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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 is 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. MSL
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. EPA CAC Cooler Corner Condition (Calculated)
8.6.4.1. Ambient Temperature: 38°C
8.6.4.2. Elevation 5500 ft.
8.6.5. Field Heat Rise
8.6.5.1. Ambient Temperature: >25°C
8.6.5.2. Elevation 1000 ft. MSL
8.6.5.3. Operation
8.6.5.3.1. Loader stockpiling at a rate of 2.5 cycles per minute at 100% fan
speed commanded through the vehicle monitor
8.7. Environment and Airborne Contaminants
8.7.1. 444L, 524L, and 544L 4WD Loaders are considered utility 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
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contaminants based on past experience. Examples of a high-debris


applications include the use of 4WD Loaders in feed-lot applications, landfills,
and loading mulch.
8.7.2. Typically, the method for dealing with cooling air side fouling of heat
exchangers 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. Fluid temperatures
8.8.1.1. Radiator
8.8.1.1.1. Minimum fluid temperature -40°C
8.8.1.1.2. Maximum fluid temperature 120°C
8.8.1.2. Fuel cooler
8.8.1.2.1. Minimum fluid temperature -40°C
8.8.1.2.2. Maximum fluid temperature 130°C
8.8.1.3. Charge air cooler
8.8.1.3.1. Minimum fluid temperature -40°C
8.8.1.3.2. Maximum fluid temperature 225°C
8.8.1.4. Hydraulic Oil cooler
8.8.1.4.1. Minimum fluid temperature -40°C
8.8.1.4.2. Maximum fluid temperature 110°C
8.8.1.5. Transmission Oil cooler
8.8.1.5.1. Minimum fluid temperature -40°C
8.8.1.5.2. Maximum fluid temperature 130°C
8.8.1.6. Axle Oil coolers (x2)
8.8.1.6.1. Minimum fluid temperature -40°C
8.8.1.6.2. Maximum fluid temperature 130°C
8.8.1.7. Condenser
8.8.1.7.1. Minimum fluid temperature -40°C
8.8.1.7.2. Maximum fluid temperature 100°C

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8.8.2. Package Arrangement


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

Figure 1 Cooling System Layout (544L)

8.8.3. Air-side Fin Density and Type


8.8.3.1. Maximum fin density is 10.5 fins per inch.
8.8.3.2. To facilitate an even air flow distribution for coolers that are parallel fin
density should be equal or similar.
8.8.3.3. Fins may not be louvered.
8.8.4. Maximum heat exchanger size including tanks. See Figure 2.

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Figure 2 Envelop Dimensions


8.8.5. Fin and Tube Material for Radiators, CACs, Condensers and Oil Coolers:
8.8.5.1. Industry standard materials are acceptable.
8.8.5.2. 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.
8.8.6. 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 butile rubber.
8.8.7. Damage Resistance
8.8.7.1. 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 water. Pressure washing testing will be conducted per EAP 9009-

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444-544L Cooling System Specification

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 sides 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 3.
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 3-7. Superimpose the
temperature tables in Figures 4-7 below on the zones indicated in Figure 3
(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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Figure 3 Cooling Package Airflow Layout (544L Pictured)

Figure 4 Steady state pre-heats for Zone 1 (TOC)


4.4°C
3.8°C

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Figure 5 Steady state pre-heats for Zone 2 (RAD/HOC)


9.2°C 10.4°C 12.0°C
HOC

6.2°C 8.6°C
10.7°C 7.4°C
RAD

Figure 6 Steady state pre-heats for Zone 3 (Condenser/fuel cooler stacked)


6.75°C 7.0°C

Figure 7 Steady state pre-heats for Zone 4 (CAC)


6.2°C
5.7°C

8.10. Fan
8.10.1. Fan weight: 3.63 kg
8.10.2. Fan rotational inertia: 0.11 kg*m2
8.10.3. Maximum fan unbalance 72 g*cm
8.10.4. Fan immersion (amount of fan inside shroud): 50%
8.10.5. Maximum fan speed (444L) 1550 rpm
8.10.6. Maximum fan speed (524L) 1700 rpm
8.10.7. Maximum fan speed (544L) 1800 rpm
8.10.8. Estimated cooling system air flow at maximum fan speed and
maximum pressure drop across total system = 0.5 kPa
8.10.8.1. 4.7 m3/s
8.10.8.1.1. ΔP Heat Exchangers = 0.25 kPa
8.10.8.1.2. ΔP Heat sheet metal = 0.25 kPa
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8.11. Variable Speed Fan Drive Control Logic


8.11.1. Fan drives with software control
Figure 8 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) 40°C 56°C
Fuel N/A N/A
Transmission 82°C 102°C
Hydraulic 63°C 96°C
Axle 85°C 95°C
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

Figure 9 Expected Coolant Flows, Minimum Water Pump Inlet Pressures and Maximum
Radiator Pressure Drops

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444-544L Cooling System Specification

Minimum Minimum Maximum


water pump water coolant Maximum
inlet pump circuit radiator
pressure at inlet pressure pressure
redline pressure drop at drop at
Engine Expected
(113°C)** at 95°C** 95°C*** 95°C****
Machine Engine speed radiator
model model (RPM) flow (l/s)* (kPa) (kPa) (kPag) (kPag)
FT4
4045
444L PSS 2200 5.3 164 103 40 30
FT4
6068
524/544L PVS 2200 7.7 159 110 50 40
 *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 include the hoses/tubes and the radiator.
 **** This is the pressure drop budget for the radiator itself.
8.13. Radiator
8.13.1. Design/Redline value used for ATR calculations 113 °C
8.13.2. Overheat sensor location. See Figure 11 Typical Coolant System
Layout Thermostat housing
8.13.3. Performance goal (Stockpiling): ATR > 48°C
8.13.4. Engineering target (Stockpiling): ATR > 53°C
8.13.5. Maximum shutdown top tank temperature 114 °C
8.13.6. Coolant warning light activation 113 °C
8.13.7. Nominal pressure cap setting 125 kPa
8.13.7.1. Cap to be supplied by vendor installed 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.

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8.13.7.2. Guideline for selecting radiator construction to meet durability


requirements: 0-160 kPa for 50,000 cycles
8.13.8. Fittings
8.13.8.1. Inlet/Outlet: 2.5 in (63.5 mm) OD beaded pipe
8.13.8.1.1. SAE J1231 – Type 2
8.13.8.2. Fill Neck of radiator not required (fill through surge tank)
8.13.8.3. Drain port thread: ¼-18 NPTF Dry Seal fitting
8.13.8.4. Drain port fitting: Petcock
8.13.8.5. Vent line: ¼-18 NPTF Dry Seal fitting
8.13.8.6. Vent line fitting: 7.94 mm (5/16 in.) OD beaded
8.13.8.6.1. SAE J1231 -Type 2
8.13.9. Engine Coolant Heat Rejection Information

Figure 10 Engine Coolant Heat Rejection

Coolant heat
Torque
Machine Engine Operating Engine speed Power rejection
model model point (RPM) (kW) (Nm) (kW)
FT4
4045
444L PSS FLRS 2200 92 400 66
FT4
4045
444L PSS FHR 2040 70 333 50
FT4
6068
524/544L PVS FLRS 2200 117.5 510 92
FT4
6068
524/544L PVS FHR 2000 80 386 60

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Figure 11 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)
8.14.1.1. Performance goal: Intake Manifold Inlet – Amb < 31 °C dT
8.14.1.2. Engineering target: Intake Manifold Inlet – Amb < 24 °C dT
8.14.2. At 38°C @ 5500 ft
8.14.2.1. Performance goal: Intake Manifold Inlet – Amb < 38 °C dT
8.14.2.2. Engineering target: Intake Manifold Inlet – Amb < 31 °C dT
8.14.3. At any ambient condition maximum intake manifold 88°C
(Warning light activation and derate)
8.14.4. Sensor location see Figure 13 Air throttle inlet
8.14.5. Maximum inlet temperature 225°C
8.14.6. Maximum inlet pressure 225 kPa

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8.14.6.1. Guideline for selecting CAC construction to meet durability


requirements: 0-350 kPa for 100,000 cycles (or 0-152 kPa for
4,000,000 cycles)

8.14.7. Fittings: Inlet/outlet: 63.5 mm (2.5 in ) OD beaded


8.14.7.1. SAE AS5131 style B
8.14.8. Engine Charge Air Cooler Heat Rejection and Pressure Drop
Information
Figure 12 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) (g/s) (kPa) (° C) (kPa (kPa) (kPa) (kPa)
FT4
4045
444L PSS 2200 92 400 168 225 175 10 5 5 3
FT4
524L
6068
544L PVS 2200 117.5 510 225 225 225 16 8 8 5

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Figure 13 Typical CAC System Layout


8.15. Fuel Cooler
8.15.1. Maximum fuel flow rate 1.7 kg/min
8.15.2. Maximum cooler internal pressure drop 10 kPa
8.15.2.1. @ fuel temperature 80°C
8.15.2.2. @ flow rate 1.7 kg/min
8.15.2.3. Guideline for selecting fuel cooler construction to meet durability
requirements: 0-100 kPa for 1,000,000 cycles
8.15.3. Maximum inlet temperature 130°C
8.15.4. Overheat sensor location High Pressure Pump
8.15.5. 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) 20°C
8.15.6. Redline value used for ATR calculations 80°C
8.15.7. Minimum ATR: 48°C
8.15.8. Fittings: Inlet/Outlet: 9.52 mm (3/8 in.) beaded tube
8.15.8.1. SAE J1231 – Type 3

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8.16. Transmission Oil Cooler


8.16.1. Working pressure
8.16.1.1. Normal Operation 700 kPa
8.16.1.2. Peak Normal Operating Pressure (Cold Ambient) 1000 kPa
8.16.1.3. Guideline for selecting transmission oil cooler construction to meet
durability requirements: 0-1400 kPa for 1,000,000 cycles
8.16.2. Minimum burst pressure 4000 kPa
8.16.3. Maximum flow rate @ 93°C 1.65 L/s
8.16.4. Maximum pressure drop @ 93°C 241 kPa
8.16.5. Max. stabilized oil temperature at sump 110°C
8.16.6. Overheat sensor location. See Figure 14 Trans
sump
8.16.7. Redline value used for ATR calculations 110°C
8.16.8. Performance goal (FHR Operation): ATR > 48°C
8.16.9. Engineering Target (FHR Operation): ATR > 53°C
8.16.10. Heat rejection
8.16.10.1.Stockpile operation (544)
8.16.10.1.1. Heat rejection: 28.6 kW
8.16.10.1.2. Oil flow rate: 1.5 l/s
8.16.11. Fittings
8.16.11.1.Inlet/Outlet: M33x2 per ISO 6149

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Figure 14 Typical TOC System Layout

8.17. Hydraulic Oil Cooler


8.17.1. Working pressure
8.17.1.1. Normal Operation 450 kPa
8.17.1.2. Peak Normal Operating Pressure (Cold Ambient) 500 kPa
8.17.1.3. Guideline for selecting hydraulic oil cooler construction to meet
durability requirements: 0-1400 kPa for 1,000,000 cycles

8.17.2. Minimum burst pressure 2000 kPa


8.17.3. Maximum flow rate @ 80°C 2.5 L/s
8.17.4. Maximum pressure drop @ 80°C 345 kPa
8.17.5. Maximum stabilized oil temperature at oil cooler inlet 104°C
8.17.6. Overheat sensor location. See Figure 15 Hydraulic filter
header

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8.17.7. Redline value used for ATR calculations 104°C


8.17.8. Performance goal (FHR Operation): ATR > 48°C
8.17.9. Engineering Target (FHR Operation): ATR > 53°C
8.17.10. Heat rejection
8.17.10.1.Stockpile operation
8.17.10.1.1. Heat rejection: 11 kW
8.17.10.1.2. Oil cooler flow rate: 1.5 l/s
8.17.10.1.3. Total system oil flow rate 2.5 l/s
8.17.11. Fittings
8.17.11.1.Inlet/Outlet: M33x2 per ISO 6149

Figure 15 Typical Hydraulic System Layout


8.18. Axle Oil Cooler
8.18.1. Working pressure

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8.18.1.1. Normal Operation 500 kPa


8.18.1.2. Peak Normal Operating Pressure (Cold Ambient) 3500 kPa
8.18.1.3. Guideline for selecting axle oil cooler construction to meet durability
requirements: 0-1400 kPa for 1,000,000 cycles
8.18.2. Minimum burst pressure 14000 kPa
8.18.3. Maximum flow rate @ 121°C 0.19 L/s
8.18.4. Maximum pressure drop @ 121°C 350 kPa
8.18.5. Maximum stabilized oil temperature at oil cooler inlet 121°C
8.18.6. Overheat sensor location. See Figure 16 AOC Inlet
8.18.7. Redline value used for ATR calculations 121°C
8.18.8. Performance goal (High Energy Braking Test): ATR > 48°C
8.18.9. Engineering Target (High Energy Braking Test): ATR > 53°C
8.18.10. Heat rejection
8.18.10.1.High Energy Braking Operation
8.18.10.1.1. Heat rejection: 3 kW per Axle (2 Axles)
8.18.10.1.2. Oil flow rate: 0.19 l/s
8.18.11. Fittings
8.18.11.1.Inlet/Outlet: -8 ORS Fitting Style A 13/16-16 Threads

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Figure 16 Typical Axle System Layout


8.19. Air Conditioning Condenser
8.19.1. Ambient temperature 43°C
8.19.2. Relative humidity 30%
8.19.3. Heat Rejection (estimated) 12 kW
8.19.4. Refrigerant mass flow rate 50.4 g/s
8.19.5. Target inlet pressure 1800 kPag
8.19.6. Maximum inlet pressure 2070 kPag
8.19.7. Inlet temperature (air) 51°C (Pre-Heat < 8 C)
8.19.8. Refrigerant super heat: 30°C
8.19.9. Refrigerant sub cooling: 6°C
8.19.10. Working Pressure: 2068 kPa
8.19.11. Maximum Pressure: 4140 kPa
8.19.12. Minimum Burst Pressure: 8270 kPa
8.19.13. Minimum Operating Temperature: -40°C
8.19.14. Maximum Operating Temperature: 107°C
8.19.15. Fittings per DTW 1046 Tube and Hose Fittings, Air Conditioner
Refrigerant
8.19.15.1. Inlet: ¾-16 UNF-2A Male Tube-O Fitting (Long Pilot)
8.19.15.2.Outlet: 5/8-18 UNF-2A Male Tube-O Fitting (Long Pilot)
8.20. Surge Tank (size chosen using E&C PV&V recommendations)
8.20.1. A surge tank shall be used to aide in meeting the fill rate, de-aeration,
drawdown, coolant expansion requirements and maintain system pressure
8.20.2. Capacity 6L
8.20.3. Expansion volume (% of system capacity) 10%
8.20.4. Coolant loss sensor is required
8.20.5. Fittings
8.20.5.1. Pressure cap: SAE 18 psi
8.20.5.2. Vent lines 8.15 mm nominal OD

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8.20.5.3. Return to water pump 33.8 mm nominal OD

Pressure cap To atmosphere

Surge Tank

Radiator Engine Water Pump


thermostat
Housing

Figure 17 Surge Tank Vent and Return Schematic


8.21. Shroud
8.21.1. Shroud construction will be of steel.
8.21.2. Shroud type will be box
8.21.3. Finger guard will be mounted to shroud with 6 mounting points
8.22. Finger Guard
8.22.1. Finger guard to meet requirements of ISO 3457 - Earth Moving
Machinery - Guards
8.22.2. Will be single piece construction
8.23. Radiator hoses
8.23.1. Adhere to DTW 1223 Radiator and Heater Hose Specification which
references SAE J20
8.23.2. Working pressure: 180 kPa
8.23.3. Minimum burst pressure per DTW 1223

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).

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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
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.
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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/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 cycle per 3 minutes
11.4.4. 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.
11.4.4.1. 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.
11.4.4.1.1. 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 25,777 hours. Failure is define as a leak
occurs.
11.4.4.1.2. Inspection interval: 200-500 cycles
11.4.4.2. Method 2: Accelerated test such as:
11.4.4.2.1. 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.
11.4.4.2.2. 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.
11.4.4.2.3. Temperature rise rate at inlet: 5ºC/sec
11.4.4.2.4. External air flow rate: 0

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11.4.4.2.5. 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.
11.4.4.2.6. Inspection interval: 200-500 cycles
11.4.5. Fatigue life prediction to meet component B50 goal of 25,777 hours.
11.4.5.1. 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: 3 minutes per cycle
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 11.5.6.
11.5.4.1.2. Inspection interval: 250 – 1000 cycles depending on total cycle
count
11.5.4.2. Method 2: Use an accelerated test such as:
11.5.4.2.1. Hot air flow of 1000 kg/hour at 230 + 5 C through heat
exchanger for 90 seconds.
11.5.4.2.2. Cold air flow of 1000 kg/hour at 180 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
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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 25,777 hours. Failure is define as
exceeding the pressure decay rate defined in Section 11.5.6.
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 25,777 hours.
11.5.5.1. See DTW 2807 Component Durability Goals Technical Specification
for All Products
11.5.6. Pressure Decay
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/hydrostatic, hydraulic and axle oil coolers.
11.6.1. Test fluid – 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 of 36,944 hours. Failure is defined as any
visible leak.
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.

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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 cycle per 3 minutes
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 of 36,944 hours. Failure is defined as any
visible leak.
11.6.3. Transmission oil cooler fatigue life prediction to meet component B50
goal of 36,944 hours.
11.6.3.1. See DTW 2807 Component Durability Goals Technical Specification
for All Products
11.6.4. Hydraulic oil cooler fatigue life prediction to meet component B50 goal
of 36,944 hours.
11.6.4.1. See DTW 2807 Component Durability Goals Technical Specification
for All Products
11.6.5. Axle oil cooler fatigue life prediction to meet component B 50 goal of
36,944 hours.
11.6.5.1. 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

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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
12.1.2. Fluid temperature 98 °C
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/hydrostatic 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/hydrostatic: See Section 8.16.4
12.2.3.2. Hydraulic: See Section 8.17.4
12.2.3.3. Axle: See Section 8.18.4
12.3. Charge Air Cooler (Internal pressure drop)
12.3.1. Fluid: air
12.3.1.1. Inlet temperature: 225°C
12.3.1.2. Inlet pressure 225 kPa
12.3.1.3. Outlet temperature 52°C
12.3.2. Measure and provide pressure drop curve vs. air flow rate

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12.3.3. Pressure drop at maximum flow rate shall not exceed limit per Section
8.14.8.
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
8.15.2

13. Burst Test


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 and 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.
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.
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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.
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 per pressure
range
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 - 200 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.

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14.4.7. Coolant Temperature: 110 +/- 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 25,777 hours.
14.4.9.1. See DTW 2807 Component Durability Goals Technical Specification
for All Products
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 36,944 hours.
14.5.9.1. 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: 100,000 or until failure
14.6.4. Fluid temperature: 90 +/-5 °C
14.6.5. Maximum cycle rate: 4 cycles/sec

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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
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, visible permanent
deformation of components, or structural cracks warrants a failure.
14.7.5. Pressure range #2: 0 kPag - 60% above rated pressure
of charge air cooler
14.7.6. Cycle Count: Test until failure
14.7.6.1. External leakage exceeding Section 20.3, visible permanent
deformation of components, or structural cracks warrant a failure.
14.7.7. Air temperature: 200 +/- 5 °C
14.7.8. Maximum cycle rate: 4 cycles/sec
14.7.9. Fatigue life prediction to meet component B50 goal of 25,777 hours.
14.7.9.1. 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)

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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 rated pressure of fuel cooler
14.8.3.4. Cycle count: Test until failure
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 rated 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.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: 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. Radiator and Coolant hoses – see SAE J1927, consult engine and cooling
PV&V. Also see V2 Net 205776.
14.10.1. Minimum sample count for each pressure level: 2
14.10.2. Test Fluid: 50/50
14.10.3. Pressure range: Dependent on working pressure

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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
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 25,777 hours.
14.10.7.1.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: 225°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 25,777 hours.
14.11.8.1.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
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B50 life as specified by DTW 3529 Structure Durability Goals Technical


Specification for All Products.
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

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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
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 2.5 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 2.5 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. 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.

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
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/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

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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
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.
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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
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

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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 J1231Formed 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
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
CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B
DATE: 2017-04-04 VERSION: JD90 50 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

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. John Deere 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
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

CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-04-04 VERSION: JD90 51 of 52
WORLDWIDE CONSTRUCTION AND FORESTRY DIVISION
SPECIFICATION
DTW 3769
444-544L Cooling System Specification

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


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

CHANGE DOCUMENT: 527867YT DESIGN CONTROL: YT REVISION: B


DATE: 2017-04-04 VERSION: JD90 52 of 52

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