JOHN DEERE HARVESTER STANDARD

JDH 803

QUALITY REQUIREMENTS FOR GRAY IRON,

NODULAR IRON, MALLEABLE IRON, OR STEEL CASTINGS
AND SALVAGE OF VISIBLE DEFECTS IN FINISHED CASTINGS
APPROVED FOR SUPPLIER
DISTRIBUTION

PURPOSE:

THIS STANDARD WILL DEFINE:

1. Types of casting defects.

2. Internal casting soundness quality requirements.
3. Visible casting defects on machined and unmachined surfaces that are not
acceptable. (CASTINGS TO BE SCRAPPED)
4. Visible casting defects on machined and unmachined surfaces that are acceptable
and do not require repair.
5. Visible casting defects on machined and unmachined surfaces that may be
repaired to salvage the casting.
6. Procedures and material to be used in repair of casting defects.

SCOPE:

1. This standard applies to internal and visible defects on Gray Iron, Nodular Iron,
Malleable Iron, and Steel Castings.
2. This standard is to be referenced on all new or revised casting drawings.
3. This standard also applies to all legacy castings purchased by John Deere
Harvester.
4. Definition of materials and methods to be used in the repair of visible casting
defects.
5. Castings salvaged per this standard do not require a deviation.
6. Castings salvaged per this standard may not be used to fulfill service part
requirements.

DATE: DATE: DATE: DATE: 26 May 2005 JDH 803

DATE: DATE: DATE: DATE:

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DEFINITION OF CASTING DEFECTS:

1. VISIBLE DEFECTS: Defects that occur on the surface of as-cast features of a

casting, or defects that are exposed when the casting is finished by any means of
machining.
2. INTERNAL DEFECTS: Defects that occur within the casting and are not visible on
the surface. They may be identified using radiographic inspection or by sectioning
of the casting.
3. GAS POROSITY OR PINHOLE DEFECT: A grouping of spherical holes as shown
in Category “A” of JDT 17015. May be visible or internal.
4. SAND HOLE OR INCLUSION DEFECT: A grouping of irregular shaped holes as
shown in Category “B” of JDT 17015. May be visible or internal.
5. SHRINKAGE DEFECT: A grouping of very small irregular shaped holes or a
grouping of dendritic shaped holes or cracks shown in Category “C” (Types CA,
CB, CC, and CD) of JDT 17015. May be visible or internal.
6. CRACK OR COLD SHUT DEFECTS: A smooth linear crack as shown in Category
“D” of JDT 17015. May be visible or internal.
7. HOT TEAR DEFECT: A jagged crack as shown in Category “E” of JDT 17015. May
be visible or internal.
8. UNFUSED CHAPLET DEFECT: A circular crack as shown in Category “F” of JDT
17015. May be visible or internal.
9. SCAB DEFECT: A thin flake of material attached to the main casting at one end
and separated from the main casting by a thin layer of sand. Visible only.

INTERNAL CASTING SOUNDNESS QUALITY REQUIREMENTS:

Note: Inspection for these types of defects is normally done by radiographic methods, or
sectioning of the casting to reveal internal areas.

1. A Gas Porosity or Pinhole Defect equal to or greater than Severity Level 4 per JDT
17015 Category “A” is not acceptable. (CASTING TO BE SCRAPPED)
2. A Sand Hole or Inclusion Defect equal to or greater than Severity Level 4 per JDT
17015 Category “B” is not acceptable. (CASTING TO BE SCRAPPED)
3. A Shrinkage Defect equal to or greater than Severity Level 4 per JDT 17015
Category “C” Type CA, CB, CC, or CD is not acceptable. (CASTING TO BE
SCRAPPED)
4. Cracks, Cold Shuts, Hot Tears, and Unfused Chaplet Defects are not acceptable.
(CASTING TO BE SCRAPPED)

VISIBLE CASTING DEFECTS THAT ARE NOT ALLOWED ON EITHER A MACHINED

OR UN-MACHINED SURFACE (CASTING TO BE SCRAPPED):

1. Crack, Cold Shut, Hot Tear, and Un-fused Chaplet Defects are not allowed.

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 2. For rotational castings such as a pulley or clutch hub no visible defects are
allowed within 3mm of the periphery.
3. For rotational castings such as a pulley or clutch hub no visible defects are
allowed within 10mm of a keyway, within 10mm of each end of a tapered or
cylindrical bore, within 10mm of each end of a cylindrical bore of a clamp or split
hub, or in any area of a spline bore.
4. SCAB DEFECTS over 30mm in any dimension are not allowed.

VISIBLE CASTING DEFECTS THAT ARE NOT ALLOWED ON A FINISHED SURFACE

OF A CASTING (CASTING TO BE SCRAPPED):

1. A Gas Porosity or Pinhole Defect equal to or greater than Severity Level 4 per JDT
17015 Category “A” is not allowed
2. A Sand Hole or Inclusion Defect equal to or greater than Severity Level 4 per JDT
17015 Category “B” is not allowed.
3. A Shrinkage Defect equal to or greater than Severity Level 4 per JDT 17015
Category “C” Type CA, CB, CC, or CD is not allowed.
4. More that (4) GAS POROSITY, SAND HOLE, or SHRINKAGE DEFECTS on any
one finished surface.
5. Any SCAB DEFECTS

VISIBLE CASTING DEFECTS THAT ARE ACCEPTABLE AND DO NOT REQUIRE

REPAIR:

1. Up to (5) singular holes in the V groove faces of pulleys and half sheaves that are
less than 0.8mm diameter and less than 1.5mm deep.
2. GAS POROSITY OR PINHOLE, SAND HOLE OR INCLUSION, or SHRINKAGE
DEFECTS of less than Severity Level 2 per JDT 17015 are allowed on unfinished
cast surfaces and non-functional finished surfaces.

VISIBLE CASTING DEFECTS THAT ARE CAN BE REPAIRED TO SALVAGE THE

CASTING:

NOTE: Salvaged castings with repaired defects may not be used to fulfill service part
requirements.

1. ANY GAS POROSITY OR PINHOLE, SAND HOLE OR INCLUSION, or

SHRINKAGE DEFECTS of less than Severity Level 4 per JDT 17015 provided that
there are not more than (4) on any one finished surface.
2. ANY GAS POROSITY OR PINHOLE, SAND HOLE OR INCLUSION, or
SHRINKAGE DEFECTS of equal to or greater than Severity Level 4 per JDT 17015
on unfinished surfaces that have not been excluded by the above requirements.
3. ANY SCAB DEFECTS of less than 30mm in dimension that have not been
excluded by the above requirements.

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REPAIR OF CASTING DEFECTS WITH EPOXY RESIN:

1) Defect Preparation:
a) Thoroughly clean the defect and surrounding surface area with DEVCON Cleaner
Blend 300 (stock #19510). Alternate cleaners are acetone or methylethylketone.
b) In the case of a Scab Defect on an as cast surface the thin flake of material
attached to the main casting at one end and separated from the main casting by a
thin layer of sand must be removed by grinding.
c) Grit blast the defect area with 8-40 mesh grit or grind with a coarse wheel or
abrasive disc pad to increase surface area for better adhesion. Desired surface
profile is 0.10 to 0.15mm with defined edges (do not feather edge).
d) Thoroughly clean the defect and surrounding surface area again with DEVCON
Cleaner Blend 300 (stock #19510). Alternate cleaners are acetone or
methylethylketone.
e) If epoxy cannot be applied immediately apply DEVCON FL-10 Primer (stock
#15980 to prevent surface corrosion or contamination. 30 minute cure time
required.

2) Epoxy Resin:

a) DEVCON Plastic Steel Putty Type A (stock #10110, 10120, or 10130). This
material can be used to repair most defects.
b) DEVCON Plastic Steel Liquid Type B (stock #10210, 10220, or 10230). This is a
liquid self leveling epoxy that may be used for very small defects that do not fill very
well with the Type A, putty.
c) Type A compressive strength = 57 MPa
d) Type B compressive strength = 70 MPa
e) Please see DEVCON Technical Data Sheets for these products available on
www.devcon.com for working conditions, mixing information, curing information etc.
f) Use of any alternative epoxy resins requires approval of John Deere Harvester
World Wide Product Development.

3) Finishing after Epoxy has cured:

a) Excess cured epoxy is to be removed with a fine grit sanding disc (= or > 120 grit).
The surface finish of the repaired area is to be equal to or smoother than the
surrounding surface.
b) The surface profile variation of an “as cast” repaired unfinished surface is to be
within a 0.25 tolerance range.
c) The surface profile variation of a repaired finished (machined) surface is to be
within a 0.1 tolerance range.

ALTERNATIVE CASTING DEFECT REPAIR METHODS:

Alternative repair methods such as Dot Welding, MIG Welding or Brazing must be
reviewed and approved by John Deere Harvester World Wide Product Development.