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John Deere Dubuque Works

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a,- Standard
DTW 1223
Radiator And Heater Hose Specification
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Scope:

This specification establishes standard construction and material requirements for cab
heater, radiator, and engine coolant bypass hoses.

Introduction:

The ultimate hose cover material would be one that has good resistance to both oils and
high temperatures. Although there are many hose cover materials that provide a portion
or all of one of these characteristics, there is none that provides both. Instead, most
tend to be in one of two categories - high temperature but low oil resistance or good oil
resistance and only moderate temperature capability. This specification embodies these
two cover types.

To assure that the appropriate hose material is selected, the engineer must decide
which of the two cover types is best for the anticipated environment. Generally the high
temperature cover will be adequate. However, if it is apparent that the hose will be
exposed to significant amounts of oil, the oil resistant cover should be chosen.

Since many coolant hose failures are caused by heat aging of the reinforcement fiber,
Kevlar or an equivalent heat resistant fiber is specified for ail applications.

Requirements:

Radiator and heater hoses must conform to SAE J20e Type 20R4 and 20A3, respectively,
with the following exceptions and additions: #

1. Tolerances

1.1 SAE J20e Commercial Tolerances are to be used unless specified otherwise,

T 10
Decision Date Decision Date Decieion Date Declaion Date lnter- Term Code
—.—.—. 279000
ASSIGNED
Fat. WAS
VERSION
Decision Date Decision Dale Decialon Date Decision Date Design
NUMBERS
86742T 06 FEB85 Con. T DTW 1223
Printed In U.S.A Pags 10t6
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John Deere Dubuque Works

Standard
- DTW 1223
Radiator And Heater Hose Specification

2. Hose Construction

2.1 Tube and cover materials

2.1.1 Material requirements for each hose a~Rlication

.. in this specification are
described in Table 1.

TABLE I
HOSE TUBE AND COVER
MATERIAL REQUIREMENTS

CONSTRUCTION
SAE
APPLICATION TYPE TUBE COVER

Radiator Outlet (water pump inlet), 20 R4 High High

Engine Coolant Bypass and Class D-1 Temperature Temperature
Radiator Inlet, High Temperature’ EPDM EPDM3

Radiator Outlet (water pump inlet), 20 R4 Oil Oil

Engine Coolant Bypass and Class C Resistant Resistant
Radiator Inlet, Oil Resistantz Polymer Polymer

Heater, High 20 R3 High High

Temperature’ Class D-1 Temperature Temperature
EPDM EPDM’

Heater, Oil 20 R3 Oil Resistant Oil Resistant

Resistantz Class C Polymer Polymer

‘For all situations except those in which the hose will be exposed to significant
amounts of oil.

‘For situations where the hose will be exposed to significant amounts of oil and to
temperatures below 150DC.

‘High Temperature EPDM should not be exposed to significant amounts of oil.

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 John Deere Dubuque Works
E%mTl Standard
DTW 1223
Radiator And Heater Hose Specification

2.2 Reinforcement

2.2.1 The reinforcement shall consist of one or more plies of knitted, braided,
or spiral wound fiber.

2.2.2 The fiber shall be Kevlar or an equivalent material that meets the
following specifications:

2.2.2.1 The hose must meet the burst requirements given in Table II
when tested per SAE J20e. These requirements are 345 kPa
(50 psi) higher than equivalent SAE J20e levels.

2.2.2.2 The hose must also provide a minimum of 85°/0 of the burst
~ levels given in Table II after undergoing the Reinforcement Heat
Resistance Test in Section 4.

2.2.3 If a reinforcement fiber other than Kevlar is proposed, the manufacturer

must submit documented test information that the fiber will meet the
above requirements, is comparable with all materials specified in both
SAE J20e and this specification, and will meet all other test
requirements given in both SAE J20e and this specification.

TABLE II
COOLANT HOSE BURST
REQUIREMENTS

SAE 20R4 SAE 20R3

SIZE BURST BURST
IN KPA Psl KPA Psl

318 1 585 230 2 065 300

1/2 1 515 220 2065 300
5/8 1 445 210 2065 300
3/4 1 375 200 1 725 250
1 1 315 190 .l 555 225
1-1/4 1 245 180 —— ——
1-1/2 1 175 170 —— ——
1-314 1 105 160 —— ——
2 1 035 150 —— ——
2-1/4 965 140 —— ——
2-1/2 895 130 —— ——

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John Deere Dubuque Works

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“PROVED FCN3 I Standard
DTW 1223
Radiator And Heater Hose Specification

3. Anti-Collaspe Wire

3.1 An anti-collapse wire (spring insert) must be used in all hoses that run from the
radiator outlet to the water pump inlet.

3.2 The wire insert must be 1.8 mm (0.070 inch) minimum diameter galvanized wire.

3.2.1 The wire must conform to ASTM A227.

3.2.2 The wire must pass a 96 hour salt spary test per ASTM B1 17.

3.2.3 Insert design must conform to Figure 1.

FIGURE 1
WIRE INSERT

O. D.*
& 1.52 mm (.06 inch)

360° OVERLAP OR I
2 FULL TURNS
.30 D MINIMUM A

For Expanded end: O. D.* = Hose I.D. & 1.52 mm (.06 inch)
For Free end: O. D.* = Hose I.D. + 0.0 mm (0.0 inch)— 3.2 mm (.125 inch)
3.3 The free length of the spring shall be such that when installed in the hose, the
spring ends are 38 Y 6 mm (1.50 a .50 inch) from either end of the hose.

3.4 “ The hose and spring insert must be such that the inlet (radiator) end of the
spring cannot be displaced more than 12 mm (0.050 inch) inward when a 22 N
(5 lb) force is applied to the end of the spring.

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m John Deere Dubuque Works

Standard
DTW 1223
Radiator And Heater Hose Specification

3.4.1 To meet this requirement, a system which provides positive retention of

the spring in the hose will probably be needed. This can be
accomplished, for example, with an enlarged end on the radiator end of
the spring and either a belled end hose or a formed reverse bead on the
inside of the hose.

4. Reinforcement Heat Resistance Test

4.1 This test shall be performed on a straight length for SAE 20R3 hose in
accordance with ASTM 380, except that the length tested shall be 254 mm
(10 in.). For SAE 20R4 hose, the same reference applies, except that the test
shall be performed on an individual curved hose.

4.2 The coolant shall consist of 10% water, 88°/0 ethylene glycol, and 2°/0 soluble
oils by volume.

4.3 The coolant temperature shall be maintained at 121 Deg. C (250 Deg. F) and
circulated through the hose at a pressure of 206 kPa (30 psi) and flow rate of
1.5 m/s (5.0 ft/see) for 200 hours. At the end of the test period, the hose shall be
burst tested per SAE J20e.

4.4 Test requirement - 85°/0 of the burst levels given in Table Il.

5. Drawing Notes

5.1 Radiator inlet and engine coolant bypass hose, high temperature:

5.1.1 “Hose must conform to DTW 1223.”

5.1.2 “John Deere part number to appear Dn hose.”

5.1.3 “HOSE CONSTRUCTION: SAE 20e R4 Class D-1 with High Temperature
EPDM tube and cover and Kevlar or equivalent fiber reinforcement.”

5.2 Radiator inlet and engine coolant bypass hose, oil resistant:

5.2.1 “Hose must conform to DTW 1223.”

5.2.2 “John Deere part number to appear on hose.”

5.2.3 “HOSE CONSTRUCTION: SAE 20e R4 Class C with Kevlar or equivalent

fiber reinforcement.”

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John Deere Dubuque Works
G’=ia Standard
DTW 1223
Radiator And Heater Hose Specification

5.3 Radiator Outlet (water pump inlet) hose, high temperature:

5.3.1 “l-lose must conform to DTW 1223.”

5.3.2 “John Deere part number to appear on hose.”

5.3.3 “HOSE CONSTRUCTION: SAE 20e R4 Class D-1 with High Temperature
EPDM tube and cover and Kevlar or equivalent fiber reinforcement, and
anti-collapse spring.”

5.4 Radiator outlet (water pump inlet), oil resistant:

5.4.1 “Hose must conform to DTW 1223.”

5.4.2 “John Deere part number to appear on hose.”

5.4.3 “HOSE CONSTRUCTION: SAE 20e R4 Class C with Kevlar or equivalent

fiber reinforcement and anti-collapse spring.”

5.5 Heater hose, high temperature:

5.5.1 “Hose must conform to DTW 1223.”

5.5.2 “HOSE CONSTRUCTION: SAE J20e R3 Class D-1 with High temperature
EPDM tube and cover and Keviar or equivalent fiber reinforcement.

5.6 Heater hose, oil resistant:

5.6.1 “Hose must conform to DTW 1223.”

5.6.2 “HOSE CONSTRUCTION: SAE J20e R3 Class C with Kevlar or equivalent

fiber reinforcement.

5.7 Material Block:

5.7.1 “See Above”

6. Reference Documents

6.1 Engineering Design Information 0510-001, “Cooling Systems” (Internal Product

Engineering Only).

6.2 JDQ 86, “Test For The Effect of Engine Coolants on Rubber Properties.”

6.3 SAE J20e

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