210-hp diesel engine endurance and performance testing with

A,19.3 1S3

No. 13322

210-HP DIESEL ENGINE ENDURANCE AND PERFORMANCE

TESTING WITH FIRE RESISTANT DIESEL FUEL:

OCTOBER 1987

Reproduced From Milad H. Mekari

• Best Available COPY U.S. Army Tank-Automotive CommandBa CATTN: AMSTA-RGE

By Warren, MI 48397-5000

IAPPROVED FOR PUBLIC RELEVUS.DISTRIBUTION IS. UNLIMITE.D

U.S. ARMY TANK-AUTOMOTIVE COMMANDRESEARCH, DEVELOPMENT & ENGINEERING CENTERWarren, Michigan 48397-5000

t___)0;.Zc' e t Y~6

NOTICES

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Destroy this report when it is no longer needed. Do not return it tothe originator.

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13322

6a. NAME OF PERFORMING ORGANIZATION 6b. OFFICE SYMBOL 7a. NAME OF MONITORING ORGANIZATION

U. S Army Tank-Automotive (If applicable)

Command AMSTA-RGE U.S. Army Tank-Automotive Command6c. ADDRESS (City, State, and ZIP Code) 7b. ADDRESS (City, State, and ZIP Code)

Warren, M! 48397-5000 Warren, MI 48397-5000

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PROGRAM PROJECT TASK WORK UNITELEMENT NO. NO. NO. ACCESSION NO.

11. TITLE (Include Security Classification)

210-HP Diesel Engine Endurance and Performance Testing with Fire Resistant Diesel Fuel (U)12. PERSONAL AUTHOR(S)

Mekari, Milad H.13a. TYPE OF REPORT 13b. TIME COVERED 14. DATE OF REPORT (Year, Month, Day) 15. PAGE COUNT

Final FROM8-11-86 TO7-29-87 October 1987 1 276

16. SUPPLEMENTARY NOTATION Intra Army order for reimbursable service, USA Belvoir, RDE Center,

CON: WI-6-60030-IB-IB, A6418

17. COSATI CODES 18. SUBJECT TERMS (Continue on reverse if necessary and identify by block number)

FIELD GROUP SUB-GROUP Fire resistant diesel fuel (FRDF), surfactant, volumepercent, mixing system, storage fuel tank, copper gasket,engine performance and endurance tests, bhp, SFC, cont.

19. ABSTRACT (Continue on reverse if necessary and identify by block number)

Four-hundred-hour endurance and performance tests were conducted at the U.S. Army Tank-Auto-motive Command on a production DT 466, 210-hp Navistar Diesel Engine with fire resistantdiesel fuel (FRDF). The FRDF contained 10.2 to 13.2 volume percent tap water. The purposeof these tests was to determine the effects of fuel-water macroemulsion on engine starting,engine fuel-wetted parts, engine power output, deposit, wear and oil degradation. Theresulics of these tests indicated that under laboratory-controlled conditions, there are noengine starting problems, deposits, oil degradation or abnormal wear.

A significant loss in horsepower (12 percent) occurred at the start of the 400-hour testwhen the engine ran with FRDF containing 10.4% volume water. A significant loss in horse-power (13.36 percent) occurred at the end of the 400-hour test when the engine ran withFRDF containing 12% volume water.

A significant increase (18 percent) in specific fuel consumption occurred at the start ofcont.

"20. DISTRIBUTION/AVAILABILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATION

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Milad H. Mekari (313) 574-5796 AMST.A-RGE

DO FORM 1473, 84 MAR 83 APR edition may be used until exhausted. SECURITY CLASSIFICATION OF THIS PAGEAll other editions are obsolete.

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Item 18. continued.

dynamometer, emulsifier, diesel fuel (DF2).

Item 19. continued.

the test when the engine ran with FRDF containing 10.4 percent volume water. The specificfuel comsumption increased to 23.91 percent when the engine ran at the end of the 400-hourtest with FRDF containing 12 percent volume water.

The delivery valve gasket of the fuel injection pump failed due to erosion caused by theFRDF.

The engine maximum torque occurred at 1,940 rpm with FRDF versus 1,800 rpm with DF2.

2

SUMMARY

The following includes pertinent product information.

* Engine:

The test engine is a diesel, 6-cylinder in line, 210-hp,2,600-rpm, direct injection, turbocharged, after cooled, model DT466, serial number 176482. It is manufactured by NavistarInternational, USA.

* Dynamometer:

Made by Eaton, model no. 1014WIG, serial no. 67637-1, powerrange 250 hp, speed range 1,800 to 6,000 rpm.

e Mixer:

Manufactured by Milton Roy Company. The mixer consists of thefollowing subsystems:

-DF2 pump of 91 gph outlet flow and 35 psi outlet pressure-water pump of 10.5 gph outlet flow and 35 psi outlet pressure-surfactant pump of 10.5 gph outlet flow and 35 psi outlet

pressure

* Motor

The motor which drives the pumps is manufactured by RelianceElectric Company. The motor's performance specifications are asfollows: 1.5 hp, 3 phase, 1,725 rpm, 230/460 volts.

o Fire Resistant Diesel Fuel (FRDF):

The FRDF is specified for this test to contain 78% volume DF2,12% volume surfactant and 10% volume tap water; however, due tothe in-line blending system's inability to regulate the waterlevel at the specified 10% volume, the actual test percentagevolume of the water ranged from 10.2 to 13.2.

3

PREFACE

This work was funded by an intra-Army order for reimbursableservice, USA, Belvoir, RDE Center. The FRDF and engine lubricantlaboratory analyses were conducted by Belvoir Fuels and LubricantsResearch Facility (SWRI).

5

TABLE OF CONTENTS

Section Page

1.0. INTRODUCTION ............... ........................ 15

2.0. OBJECTIVE .................. ............................ 15

3.0. CONCLUSIONS ................ ......................... ... 15

4.0. RECOMMENDATIONS ................ ........................ 15

5.0. DISCUSSION ................. ......................... .. 165.1. Test Program ............... ........................ .. 165.2. Performance Analysis for Engine Operation with DF2 vs. FRDF. 335.2.1. Horsepower (hp) Loss and Specific Fuel Consumption (SFC)

Increase due to the Engine Operation with DF2 vs. FRDF with10.4 Percent Volume Added Tap Water. ................... ... 33

5.2.2. Horsepower Loss and SFC Increase due to Engine Operationwith DF2 vs. FRDF with 12 Percent Volume Added Tap Water . . 34

5.2.3. Horsepower and SFC Losses using FRDF at the End of 400-HourEndurance Test with FRDF .............. .................. 34

5.3. Inspection Results ............ ..................... .. 365.3.1. Fuel Injection System Inspection .......... .............. 365.3.2. Nozzles Opening Pressure Inspection ..... ............. ... 365.3.3. Engine Inspection ........... ...................... ... 365.4. Oil and Filter Changes ........... ................... .. 385.5. Horsepower and Torque versus rpm ........... .............. 38

APPENDIX A. ANALYSIS OF FUELS AND LUBRICANTS ..... ............ A-1APPENDIX B. NATO STANDARD DIESEL AND SPARK IGNITION ENGINE LAB TEST

SPECIFICATIONS ........... ..................... B-1APPENDIX C. SAMPLE TEST SHEETS ............ ................... .C-1APPENDIX D. PHOTOGRAPHS ....................... D-1APPENDIX E. DIMENSIONAL ANALYSIS ................. E-1

DISTRIBUTION LIST .................. ......................... .. Dist-I

7

LIST OF TABLES

Table Title Page

5-1. Engine Specification ............ ..................... .. 17

5-2. FRDF and DF2 ................ ......................... ... 18

5-3. Dynamometer Specification .......... ................... ... 19

5-4. Test Cell Preparation and Tests Outline ..... ............ .. 20

5-5. Safety Shutdown Parameters ........... .................. ... 21

5-6. Temperature Ranges of the Thermocouples ..... ............ . 22

5-7. Pressure Ranges of the Transducers ....... .............. ... 23

5-8. Warning--Shutdown Temperatures ............. ................ 24

5-9. Warning--Shutdown Pressures ........ .................. ... 25

5-10. Engine Break-In Run ............ ..................... .. 26

5-11. Initial Engine Performance Test with DF2 Fuel ........... .. 27

5-12. Development of Part-Load Performance Data from Full-Load100% Performance Run for DF2 Fuel ........... .............. 28

5-13. Development of Part-Load Performance Data from Full-Load100% Performance Run for FRDF ......... ................ ... 29

5-14. 400-Hour NATO Endurance Test with FRDF ..... ............ .. 30

5-15. Instruments and Equipment ........... .................. ... 31

5-16. Test Samples and Test Conclusion .......... ............... 32

5-17. Brake Horsepower and Brake Specific Fuel Consumption of theEngine Using DF2 and FRDF ........... .................. ... 35

5-18. Nozzles' Opening Pressure Inspection ..... ............. .. 37

5-19. Performance Test Data (100% Load, DF2, 0-Hour) .......... ... 39

5-20. Performance Test Data (85% Load, DF2, 0-Hour) ........... .. 40


9

LIST OF TABLES (Continued)

Table Title Page

5-22. Performance Test Data (50% Load, DF2, 0-Hour) ........... ... 42

5-23. Performance Test Data (25% Load, DF2, O-Hour) ........... ... 43

5-24. Performance Test Data (100% Load, FRDF, 0-Hour) ... ....... 44

5-25. Performance Test Data (85% Load, FRDF, 0-Hour) ........... ... 45

5-26. Performance Test Data (70% Load, FRDF, 0-Hour) ........... .. 46



5-29. Performance Test Data (100% Load, FRDF, 100-Hour) .......... 49

5-30. Performance Test Data (100% Load, FRDF, 200-Hour) ........... 50


5-32. Performance Test Data (100% Load, FRDF, 400-Hour) ......... .. 52


5-34. Performance Test Data (70% Load, FRDF, 400-Hour) .... ....... 54



5-37. Performance Test Data (100% Load, DF2, 400-Hour) ......... .. 57







5-44. Performance Test Data (Lubricating Oil Consumption) ......... 64

5-45. Performance Test Data (at the end of 10-Hour) ............ .. 65

10


Table Title Page

5-46. Performance Test Data (at the end of 20-Hour) ........ 66

5-47. Performance Test Data (at the end of 30-Hour) ........... .. 67

5-48. Performance Test Data (at the end of 40-Hour) . . . ... .. 68





5-53. Performance Test Data (at the end of 90-Hour) ........... ... 73

5-54. Performance Test Data (at the end of 100-Hour) ..... ........ 74










5-64. Performance Test Data (at the end of 200-Hour) ..... ........ 84






1i


Table Title Page





5-74. Performance Test Data (at the end of 300-Hour).. ..... ...... 94







5-81. Performance Test Data (at the end of 370-Hour) ........... .101




5-85. Properties of Reference Diesel Fuels .... ............. .. 105

12

LIST OF ILLUSTRATIONS

Figure Title Page

5-1. Schematic Flow Diagram of FRDF Blending System ........... .. 106

5-2. Performance Test Diagram (100% Load, DF2, 0-Hour) ........... 107

5-3. Performance Test Diagram (85% Load, DF2, 0-Hour) ......... .. 108

5-4. Performance Test Diagram (70% Load, DF2, 0-Hour) ......... .. 109

5-5. Performance Test Diagram (50% Load, DF2, 0-Hour) .... ....... 110

5-6. Performance Test Diagram (25% Load, DF2, 0-Hour) .......... 111

5-7. Performance Test Diagram (100% Load, FRDF, 0-Hour) .......... 112

5-8. Performance Test Diagram (85% Load, FRDF, 0-Hour) ........... 113




5-12. Performance Test Diagram (100% Load, FRDF, 100-Hour) ......... 117

5-13. Performance Test Diagram (100% Load, FRDF, 200-Hour) ..... ... 118

5-14. Performance Test Diagram (100% Load, FRDF, 300-Hour) ... ..... 119






5-20. Performance Test Diagram (100% Load, DF2, 400-Hour) ......... 125

13

LIST OF ILLUSTRATIONS (Continued)

Figure Title Page

5-21. Performance Test Diagram (85% Load, DF2, 400-Hour) ........ .. 126





5-26. Performance Test Diagram (50% Load, FRDF, 400-Hour) .......... 131

5-27. Performance Test Diagram (HP at 100% Load for DF2 and FRDF).. 132

5-28. Performance Test Diagram (SFC at 100% Load for DF2 and FRDF) . 133

5-29. Performance Test Diagram (Torque at 100% Load DF2 and FRDF).. 134

5-30. Performance Test Diagram (HP at 85% Load for DF2 and FRDF) . . 135

5-31. Performance Test Diagram (SFC at 85% Load, for DF2 and FRDF) . 136

5-32. Performance Test Diagram (Torque at 85% Load, for DF2and FRDF) ............... ........................... ... 137

5-33. Performance Test Diagram (HP at 70% Load, for DF2 and FRDF).. 138

5-34. Performance Test Diagram (SFC at 70% Load, for DF2 and FRDF) . 139

5-35. Performance Test Diagram (Torque at 70% Load, forDF2 and FRDF) ............. ......................... ... 140

5-36. Performance Test Diagram (HP at 50% Load for DF2 and FRDF) . . 141

5-37. Performance Test Diagram (SFC at 50% Load for DF2 and FRDF). . 142

5-38. Performance Test Diagram (Torque at 50% Load forDF2 and FRDF) ............. ......................... ... 143

5-39. Performance Test Diagram (HP at 25% Load for DF2 and FRDF) . 144

5-40. Performance Test Diagram (SFC at 25% Load for DF2 and FRDF). 145

5-41. Performance Test Diagram (Torque at 25% Load for DF2and FRDF) ............... ........................... ... 146

14

1.0. INTRODUCTION

The test program and report were conducted and prepared by the U.S.Army Tank-Automotive Coammand Propulsion Systems Division andlaboratory. The report details performance and durability tests usingFire Resistant Diesel Fuel (FRDF). The objective of the FRDF programis to develop a future fuel that will reduce the vulnerability ofmilitary vehicles to fire, decrease the number of vehicles lost andrepair costs, and increase crew survivability.

2.0. OBJECTIVE

The objective of this project is to evaluate the performance andendurance of a medium-sized, unmodified conmmrcial production dieselengine of 200-hp range tested with FRDF. The FRDF contains tap waterof 10.2 to 13.2 percent volume.

Another objective of this project is to inspect the fuel-wetted partsof the fuel injection system and engine, and determine the effect ofthe water in the fuel on these parts.

3.0. CONCLUSIONS

The FRDF was tested with an engine and a fuel injection system designedto operate with diesel fuel. The engine did pass the 400-hourendurance test with the exception of the delivery valve gasket. Thedelivery valve gasket failed at the 388th hour of endurance testing.This failure was due to the FRDF chemical attack on the gasket's coppermaterial.

The storage stability of the FRDF lasted for 2 weeks. The mixer didnot give the intended mixing ratio. The tap water ratio in the FRDFvaried between 10.2 to 13.2 percent volume.

4.0. RECOMMENDATIONS

In order to benefit from the FRDF's positive characteristics and makethe negative characteristics acceptable, the FRDF research anddevelopment program should continue. Continuation of the laboratory'sengine testing and initiation of field vehicle tests per plannedmission profile are essential for the success of this program.

Other issues which should be addressed are:

"* Storage life improvement of the FRDF,

"* Design improvement of the blending system of the FRDF,

"* Incorporation of a fuel heating device into the vehiclefuel system for cold-weather operation with FRDF below00c.

15

* Redesign of the engine and fuel injection system partswhich failed and/or eroded because of the use of FRDF, and

* Development of a logistics support plan.

5.0. DISCUSSION

5.1. Ts rga

The purpose of the DT-466 Navistar Diesel Engine 400-Hour Durabilityand Performance Test with FRDF is to determine the effects of tap waterblended with diesel fuel on the performance and durability of theengine's fuel injection system (fuel pump and injectors), pistons,rings, cylinders, cylinder head and valves, and to detrmine how a ratedperformance and proven durability of a commercial diesel engine willchange. Test location was Building 212, Cell no. 1, TACCM. See Tables5-1 through 5-16 for detailed test equipment and test programinformation.

16

Table 5-1. Engine Specification

Engine Model: DT 466, SIM 467-TM2U176482Rated full-load power, without fan, with air cleaner: 210 hp at2,600 rpmNumber of Cylinders: 6-cylinder in lineType: 4 stroke per cycle, compression - ignition, turbochargedBore: 4.301 in.Stroke: 5.350 in. 3Displacement: 466.4 in.Compression ratio: 16.3:1Dry Engine Weight: 1,400 lbsFiring Order: 1-5-3-6-2-4Lubricating Oil: MIL-L-21040 - Grade 15W40Fuel Injection Pump: MW, S/N 24581842

17

Table 5-2. FRDF and DF2

1. Planned percentages of the FRDF are:

78% DF210% tap water12% Surfactant (Emulsifier)

2. Due to the faulty functioning of the mixer during the mixingprocess, the percentages were different fram those planned above.The actual test percentages of the FRDF mixture are stated in thetables of this report.

3. Fuel to be used for break-in, initial and final performancetest is DF2.

4. Fuel to be used in the 400-hour durability and performancetests is FRDF.

18

Table 5-3. Dynamometer Specification

Made by EatonModel No.: 1014WIGSerial No.: 67637-1Power Range: 250 hpSpeed Range: 1,800 to 6,000 rpmTorque Arm: 21.008 in.DC Excitation: 220 volts - 2.6 amps

59 OHMs and 20 °CWater Requir~nents: 18 GPM max. at 35 psi min. and 100 psi max.

19

Table 5-4. Test Cell Preparation and Tests Outline

* In cell no. 1, install DT 466 diesel engine together withcooling water tower and dynamometer. Install instrumentation,temperature and pressure thermocouples and probes. Use theexisting Elwood recording data system.

* Install all required pressure lines, speed and load cellsconnections, fuel throttle lever, shut-off lever, aneroidassembly, exhaust and intake air connections; provide emergencyfuel shutoff and warning lights. Shut down system for criticaltemperature, pressure and rpm limits on engine and dynamometer.Engine blow-by volume and pressure is to be recorded during fullpower performance. Engine's air, oil, coolant, temperature,pressure and exhaust gas temperature will be monitored andrecorded.

* Test cell air depression: 1.2 in H[2 0 max.

Outline of Tests

1. Prepare engine for performance and endurance tests, installinstrumentation, calibration of instrumentation and equipment,engine operating limits, adjustment and instrumentationcheckout.

2. Break in run with DF2 (see Table 5-10).

3. Test for performance, full and part loads with DFt (Table5-12).

4. Test for performance, full and part l6ads with FRDF (Table5-13).

5. Run 400-hour NATO durability test with FRDF. Part- and full-load data are from FRDF performance data (see Table 5-13).

6. At the end of each 100-hour durability test, check the enginefor full-load performance.

7. At the conclusion of the 400-hour durability run, test theengine for full- and part-load performance on FRDF and DF2.

8. For maintenance procedures refer to Section 2-4 of the NATOstandard diesel and spark ignition engines laboratory test, Jan 84(see Appendix A).

* At the start of each test, record the barometric pressure,temperature and relative humidity.

* At the conclusion of performance tests with DF2 fuel, test theengine with FRDF to obtain full-load performance data. Follow thesame procedures followed with DF2 fuel and record full- andpart-load performance using Table 5-13.

20

Table 5-5. Safety Shutdown Parameters

Parameter Engine Shutdown

Coolant temperature measured at rear of cylinder head 210°F max

Engine blow - by at rated power 6 cu ft/min max

Exhaust temperature, turbine inlet 1350°F max

Exhaust temperature, turbine outlet 1150°F max

Oil gallery pressure:

Cycle test 10 PSI min

Full load test 30 PSI min

Crankcase pressure 6" H20 max

Overspeed 3200 RPM max

Underspeed 600+ 25 RPM

Oil temperature 2650 F max

0 The restriction measured at full load and rated speed in the fuel linebetween the primary filter and the fuel supply pump should not exceed 6inches of Hg.

* The engine blow-by thru the breather at rated speed and power of 2600 RPMand 210 HP is 6 CFM at 6 inches of H2 o maximu'n.

0 The test air cleaner flow at rated engine's power speed is 1100 CFM.

21

Table 5-6. Temperature Ranges of the Thermocouples

Thermocouple Range Accuracy

".F

Air, cell anbient 60-120 +2

Air, cleaner inlet 60-120 +2

Air, cleaner outlet 60-120 +3

Air fran Turbocharger 60-300 +3

Fuel spillback after pnp 60-150 +3

Exh. outlet (before and after turbo) 500-1700 +5

Exhaust ports 500-1700 +5

Fuel (before fuel pump) 60-120 +3

Fuel at secondary filter 60-150 +10

Coolant, engine-outlet and inlet 120-250 +3

Cooling water tower, inlet 35-100 +3

Cooling water tower, outlet 35-250 +3

Engine oil 60-300 +3

Instrumentation bath 150-250 +3

22

Table 5-7. Pressure Ranges of the Transducers

Pressure Range Transducer Data Point

-4.16 in H20 .15 PSI Cell depression

-27.76 in H20 1.0 PSI Air before turbo

27.76 in H20 1.0 PSI Air cal. orifice

27.76 in H2 0 1.0 PSI Air crankcase

83.30 in H20 3.0 PSI Exhaust after turbo

61.23 in Hg 30.0 PSI Air after turbo

61.23 in Hg 30.0 PSI Exhaust before turbo

30.0 PSI 30.0 PSI Fuel after engine filters

30.0 PSI 30.0 PSI Fuel pump spillback

30.0 PSI 30.0 PSI Fuel injectors spillback

100.0 PSI 100.0 PSI Oil engine gallery

100.0 PSI 100.0 PSI Coolant engine in

100.0 PSI 100.0 PSI Coolant engine out

100.0 PSI 100.0 PSI Cooling water tower in

300.0 PSI 300.0 PSI Dyno water in

23

Table 5-8. Warning-Shutdown Temperatures

Data Point T_7 warning ShutdownF oF FF

Air ambient in test cell 77+5Air before air cleaner 77+5Air after air cleanerAir after turboOil sump 255 265Oil Gallery 255 265Oil after turbo 255 265Fuel before engine filters 86+4Fuel after engine filtersFuel spillback (ccmbined)Coolant engine inCoolant engine out 205+4 210 215Cooling water in (tower)Cooling water out (tower)Dyno water out 140 145Reference bathExhaust port No. 1 1300 1350Exhaust port No. 2 1300 1350Exhaust port No. 3 1300 1350Exhaust port No. 4 1300 1350Exhaust port No. 5 1300 1350Exhaust port No. 6 1300 1350Exhaust before turbo - front 1300 1350Exhaust before turbo - rear 1300 1350Exhaust after turbo 1100 1150

24

Table 5-9. Warning--Shutdown Pressures

Data Point Pressure Warning Shutdown

Air cell depression

Air before turbo (T) -10+2" H2 0

Air before turbo (S)

Air calibrated orifice

Air crankcase 4" H20 6" H20

Exhaust after turbo (S) 16+2" H20 20" H20 25" H20

Air after turbo (boost)

Exhaust before turbo

Fuel before engine filter

Fuel spillback (inj + pump)

Oil engine gallery 12-PSI 10 PSI

Coolant engine in

Coolant engine out

Cooling water tower in 40 PSI 30 PSI

Dyno water in 10 PSI 8 PSI

Fuel after engine filters

25

Table 5-10. Engine Break-in Run

.4-W cu

0 c 0.

Al ~ 0 c a14 X

co 4j

c.w 00a4)

:34J 0J

w -0 44 4~

mC)>

'0

cc4. XC(0 0) U-4- ),

'0 '-n U 0 "a) 4 w. tDIt t.fl4 mm% - -o m wmr-0 sa 4w )

N) m~ C)wr o0 MmMmý -comi - 4

ý4 rA 1-4ý4 P-I -40)i r I r4 C) C).4 N0q c -4r4- N N c

-'-44 44 O

4-JO CD i 0 a)0v Cfl r. ~ %D 0

W )-rIC)) E-4 0C U

N 0 cd 0

a) -4 C) 0

41 -L 'm -Cu, 4~ vI0 1.4C 41

U -4 0 0 0

0) C)( 0I4.) 4 0 0

U0 0 U3 --t

co to -vIU4, a. c (U a)

4j -14 0) ) CU

C ~ >

40) Q) z ) C ~ 1-H -1-14- a) ý 4C C~

4-1 ( - 0.Z .-H

a)-0 ) 4- )

260"j -

Table 5-11. Initial Engine Performance Test with DF2 Fuel

For initial engine performance test use DF2 fuel. Test the enginefor performance and record the data as follows:

9 Full-load performance test

-The full-load (full-rack) performance test, bhp, fuelconsumption, torque, bmep and bsfc data, will be recorded at aseven-speed setting, two of these settings at the rated torquespeed of 1,800 rpm and the rated hp speed of 2,600 rpm.

-The seven speed settings are to start at 1,400 rpm withincrements of 200 rpm for each setting.

-For each setting, the engine should be run for a sufficienttime to allow the operating parameters to stabilize.

* Part-load performance test of 85%, 70%, 50% and 25% of the fullload

-Using throttle control and the dynamometer, test the engineand record complete data for each of the four part-load settingsof 85%, 70%, 50% and 25% of the full-load test.

-Each part-load setting is to be tested with the aboveestablished seven speed settings, starting at 1,400 rpm and endingat 2,600 rpm with 200-rpm increments.

No correction factor will be applied and the test results mustinclude air cell temperature, atmospheric and cell pressure andhumidity.

9 Go to Table 5-12.

27

Table 5-12. Development of Part-Load Performance Data from Full-Load100% Performance Run for DF2 Fuel

LOAD RPM TORQUE

100% 1400 4551600 4931800 5172000 4962200 459

2400 4472600 422

85% 1400 3871600 4191800 4392000 4222200 3902400 3802600 359

70% 1400 3181600 3451800 3622000 3472200 3212400 3132600 295

50% 1400 2271600 2461800 2582000 2482200 2292400 2232600 211

25% 1400 1141600 1231800 1292000 1242200 1152400 1122600 105

28

Table 5-13. Development of Part-Load Performance Data from Full-Load100% Performance Run for FRDF

o At the conclusion of performance tests with DF2 fuel, test the enginewith FRDF to obtain full-load performance data. Follow the same proceduresfollowed with DF2 and record full- and part-load performance using thefollowing table:

LOAD RPM TORQUE

100% 1400 3831600 4071800 4312000 4292200 4102400 3992600 371

85% 1400 3271600 3461800 3662000 3642200 3482400 3392600 315

70% 1400 2681600 2851800 3012000 3002200 2872400 2792600 259

50% 1400 1911600 2031800 2152000 2142200 2052400 1992600 195

25% 1400 961600 1021800 1082000 1072200 1022400 1002600 93

29

Table 5-14. 400-Hour NATO Endurance Test with FRDF

The endurance test duration is 400 hours divided into four periodsof 100 hours each. At the completion of each period, the engine shallbe submitted to a full-load performance check.

Each 100-hour period is to comprise ten (10) hour cycles. Each 10-hourcycle will be carried out in accordance with the following program:

Program of 10 Hour Cycle

Subcycle % Rated Speed % Load Duration in Hours

1 IDLE 660+ 25 RPM 0

2 100 2600 RPM 100 2

3 2900+ 25 RPM 0

(GOVERNED SPEED)

4 75 1950 RPM 100 1

5 IDLE ------ 100 0 - 00 2660+ 25 2600 RPM 4 MIN 6 MIN

6 60 1560 RPM 100

7 IDLE 660+ 25 RPM 0

8 2700+ 25 RPM 70(GOVERNED SPEED)

9 MAX TORQUE SPEED1800 RPM 100 2

10 60 1560 RPM 50

NOTE: Conduct the maintenance, oil change, oil and fuel filterchange and data recording; per Part II of NATO StandardDiesel and Spark Ignition Engines Laboratory Test(Revised Jan 84) Section 2-4, . (See Appendix B.)

30

Table 5-15. Instruments and Equipment

* Instruments to be Used in the Test Program

-Elwood data acquisition system to be used for data gathering.

-Load cell to be used for measuring torque.

-Digital Elwood fuel weigh system to be used for measuringfuel.

-Cooling tower system.

-Engine blow-by measuring system.

-Oil bath temperature.

9 Calibration of Instruments and Equipment

-The instrumentation and equipment used in the test cell willbe calibrated prior to the start of the test and within rangesspecified in previous paragraphs of this report.

* Further instructions will be given by the engineer when it isnecessary during the test.

* Daily before every start up of testing, check coolant and oillevels and check for loose bolts, nuts, brackets, harnesses andcracks. Correct the problem and report it to the projectengineer. Record the above in the log book in detail.

0 Air-operated torque wrench should not be used on rotatingengine parts.

* Provide high-visibility transparent fuel line near control roomwindow.

31

Table 5-16. Test Samples and Test Conclusion

* FRDF and Oil Samples

1. Each 50 hours of durability testing, take 8 ounces of fuelsample at the mixer for laboratory analysis at Belvoir Fuels andLubricants Research Facility (SWRI).

2. Take 2 ounces of oil sample before starting endurance test andevery 50 hours thereafter from oil gallery.

3. Check engine oil level and appearance at completion of everyshift or before engine is started for a new day of tests.

4. Record data during the last five minutes of each of theendurance periods listed in test schedule.

o Test Conclusion

1. At the conclusion of the 400-hour durability test disassembleand inspect the following:

-Fuel injection pump-Injectors-Engine's rotating and reciprocating parts

2. Prepare report.

The end of test program.

32

5.2. Performance Analysis for Engine Operation with DF2 vs. FRDF

5.2.1. Horsepower (hp) Loss and Specific Fuel Consumption (SFC)Increase due to the Engine Operation with DF2 vs. FRDF with 10.4Percent Volume Added Tap Water. (See Table 5-17.)

208 - 183 = 25 hp

208 hp = maximum engine rated hp with DF2, and 0-hour endurance

183 hp = maximum engine rated hp with FRDF containing 10.4% addedtap water, full load and at 0-hour endurance

25 hp = lost hp due to the use of FRDF

25 x 100 = 12% of hp decrease208

0.484 - 0.410 = 0.074

0.484 lbhp-hr = specific fuel consumption rate with FRDF containing

10.4% volume added tap water, 100% engine load, rated rpm and at 0-hourendurance

0.410 lbhp-hr = specific fuel consumption rate with DF2, 100% engine

load, rated rpm and at 0-hour endurance.

0.074 lbhp-hr = specific fuel consumption increase due to the use of

FRDF

33

0.074 * 1000.410 = 18% of SFC increase due to the use of FRDF with

10.4% volume added tap water.

5.2.2. Horsepower Loss and SFC Increase due to Engine Operation withDF2 vs. FRDF with 12 Percent Volume Added Tap Water (see table5-17).

202 - 175 = 27 hp

202 hp = maximum engine hp with DF2 and 400-hour endurance

175 hp = maximum engine hp with FRDF containing 12% volume addedtap water and at 400-hour endurance

27 hp = lost hp due to the use of FRDF with 12% volume added tapwater.

27 x 100 = 13.36% of hp decrease202

0.513 - 0.414 = 0.099 lbhp-hr

0.513 lbhp-hr = specific fuel consumption rate with FRDF containing

12% volume added tap water, 100% engine load, rate rpm and at 400-hourendurance

0.414 lbhp-hr = specific fuel consumption rate with DF2, 100% engine

load, rated rpm, and at 400-hour endurance.

0.099 lbhp-hr = specific fuel consumption increase due to the use of

FRDF with 12% volume added tap water

0.099 * 1000.414 = 23.91% of SFC increase due to the use of FRDF with

12% added tap water

5.2.3. Horsepower and SFC Losses using FRDF at the End of 400-HourEndurance Test with FRDF.

183 - 175 = 8 hp

8 * 100183 = 4.37 % of hp decrease tested with FRDF at the end of

the 400-hour endurance test with FRDF

0.513 - 0.484 = 0.029 lbbhp-hr

0.029 * 1000.484 = 5.99% 6% of SFC increase at the end of 400-hour

endurance test

34

Table 5-17. Brake Horsepower and Brake Specific Fuel Consumption

of the Engine Using DF2 and FRDF

Fuel Engine Rated Engine Added hp bsfc % hp % SFC% Load Engine Endurance % Vol lb decrease increase

rpm hrs water 1pEi

DF2 100 2,600 0 0 208 .410 0 0

DF2 100 2,600 400 0 202 .414 2.88 1

FRDF 100 2,600 0 10.4 183 .484 12 18

FRDF 100 2,600 400 12 175 .513 13.36 23.91

35

5.3. Inspection Results

5.3.1. Fuel Injection System Inspection. At the conclusion of the400-hour NATO cycle test, the fuel injection system was disassembledfor visual and dimensional inspection. The visual inspection showedthe following:

"* The nozzles were in good condition except for signs ofheat buildup on the guide portion of the nozzle valvestem.

"* The plungers, barrels, springs and delivery valves were ingood condition.

"* The delivery valve gasket (second rear) failed at 388hours of durability testing, causing a fuel leak outsidethe pump. The failed valve gasket was replaced by a newone and the test continued.

"* The remaining gaskets eroded to their near outsidediameter, but completed the test without fuel leak.

"* The gasket's erosion was caused by the chemical attack ofthe oleic acid, contained in the FRDF on the coppermaterial gaskets.

"* The clamping forces on the failed and eroded gaskets wereadequate, based on the amount of knife edge deformation onthe discharge fittings.

"* The fuel lines and remaining parts of the fuel injectionsystem were in good condition.

5.3.2. Nozzles Opening Pressure Inspection.

"* The design specification of the nozzle opening pressure is3,600 to 3,750 psi and the service specification of theopening pressure is 3,000 to 3,250 psi.

"* Test nozzles' opening pressures after engine endurancetests were within the service specification limits as inTable 5-18.

5.3.3. Engine Inspection. At the conclusion of the 400-hour NATOcycle test, two pistons of the engine (numbers one and three) wereremoved fram the crankcase and all valves removed fram the cylinderhead for visual and dimensional inspection. The visual inspectionshowed the following:

* Piston pressure ring faces exhibited slight wear rate,however, they were still in satisfactory condition.

* Pistons and valves were in good condition with no evidenceof chemical erosion or corrosion.

36

Table 5-18. Nozzles' Opening Pressure Inspection (PSI)

Nozzle Number Opening Pressure

1 3,280

2 3,430

3 3,400

4 3,500

5 3,320

6 3,470

NOTE: These opening pressures fall within the service opening pressurerange.

37

"* The carbon deposit levels on these parts were light to

moderate.

"* The remaining parts were in good condition.

5.4. Oil and Filter Changes

Oil, oil filter and fuel filter changes were performed five timesduring the engine test. Changes were performed at the end of thebreak-in test and after each 100-hour durability test.

5.5. Horsepower and Torque versus rpm

"* The maximum horsepower with FRDF occurred at 2,500 rpm andcontinued nearly constant throughout 2,600 rated enginerpm on most of the performance curves.

"* The maximum rated horsepower with DF2 occurred at 2,600

rpm.

"* The maximum torque with FRDF occurred at 1,940 rpm.

"* The maximum rated torque with DF2 occurred at 1,800 rpm.

See the tables (5-19 through 5-85) and figures (5-1 through 5-41)contained in this report for more information on performance testdata.

38

Table 5-19. Performance Test Data(100% Load, DF2, 0-Hour)

PERFORMANCE TEST DATA

DT-466 NAVISTAR DIESEL ENGINE S/N 176482

100% LOAD

DIESEL FUEL (DF2)

ENDURANCE TEST HOURS: 0

TOTAL OPERATING HOURS: 28

1B 1BRPM 1B-FT BHP HR BHP-HR BMEP

1400 455 121 45.0 0.371 147.2

1600 493 150 52.6 0.350 159.0

1800 517 177 64.1 0.361 167.3

2000 496 188 68.1 0.362 160.5

2200 471 197 73.8 0.384 148.5

2400 442 202 79.48 0.393 143.0

2600 422 208 85.3 0.410 136.5

2888

39

Table 5-20. Performance Test Data (85% Load, DF2, 0-Hour)



85% LOAD

DIESEL FUEL (DF2)



1B lBRPM lB-FT BHP HR BHP-HR BMEP

1400 386 103 37.4 0.365 124.9

1600 419 127 44.7 0.349 135.5

1800 439 150 53.3 0.354 142.0

2000 422 160 58.1 0.361 136.5

2200 401 168 60.8 0.370 126.8

2400 380 173 68.56 0.396 122.9

2600 439 177 73.0 0.412 116.1

2888

40




70% LOAD

DIESEL FUEL (DF2)



1B 1BRPM lB-FT BHP HR BHP-HR BMEP

1400 317 84 28.4 0.336 102.5

1600 346 105 36.2 0.344 111.9

1800 362 124 44.1 0.355 117.1

2000 347 132 48.1 0.364 112.2

2200 329 138 51.2 0.381 103.8

2400 313 143 56.36 0.395 101.2

2600 295 145 61.8 0.423 95.4

2888

41

Table 5-22. Performance Test Data (50% Load,- DF2, 0-Hour)



.50% LOAD

DIESEL FUEL (DF2)



lB lBRPM lB-FT BHP HR BHP-HR BMEP

1400 227 60 22.3 0.368 73.4

1600 246 74 27.8 0.370 79.6

1800 257 88 32.6 0.370 83.1

2000 248 94 36.4 0.385 80.2

2200 236 99 38.4 0.400 74.1

2400 223 101 42.9 0.421 72.1

2600 211 104 46.7 0.447 68.2

2888

42




25% LOAD

DIESEL FUEL (DF2)



1B 1BRPM lB-FT BHP HR BHP-HR BMEP

1400 113 30 13.3 0.441 36.5

1600 123 37 16.4 0.437 39.8

1800 129 44 18.0 0.407 41.7

2000 124 47 21.'8 0.462 40.1

2200 118 49 23.3 0.483 37.2

2400 112 51 27.2 0.531 36.2

2600 105 51 30.0 0.577 33.9

2888

43

Table 5-24. Performance Test Data (100% Load, FRDF, 0-Hour)



100% LOAD

FIRE RESISTANT DIESEL FUEL (FRDF)



1B lRPM lB-FT BHP HR BHP-HR BMEP

1400 383 102 43.3 0.424 123.9

1600 407 124 52.5 0.422 131.7

1800 431 147 62.5 0.425 139.4

2000 429 163 69.1 0.422 138.8

2200 419 175 76.9 0.439 132.6

2400 399 182 82.1 0.450 129.1

2600 371 183 88.9 0.484 120.0

2888

FRDF CONTENT:

78. VOL % DF2

11.6 VOL % SURFACTANT (E7ULSIFIER)

10.4 VOL % Detroit Tap Water

44




85% LOAD




RPM IB-FT BHP HR BHP-HR BMEP

1400 321 85 33.6 0.392 103.8

1600 348 105 44.1 0.416 112.6

1800 363 124 52.2 0.420 117.4

2000 365 138 55.9 0.434 118.1

2200 351 147 65.4 0.444 113.5

2400 339 154 72.0 0.464 109.6

2600 317 156 77.2 0.492 102.5

2895 40 22 28.2 1.011 12.9

FRDF CONTENT:

78 VOL % DF2

11.6 VOL % SURFACTANT (EMULSIFIER)

10.4 VOL % WATER

45




70% LOAD




1B 1B

RPM IB-FT BHP HR BHP-HR BMEP

1400 266 70 29.3 0.413 86.0

1600 287 87 35.4 0.427 92.8

1800 302 103 43.9 0.424 97.7

2000 299 113 50.3 0.441 96.7

2200 291 120 54.8 0.455 92.8

2400 279 127 60.4 0.473 90.2

2600 260 128 65.7 0.510 84.1

2895

FRDF CONTENT:

78 VOL % DF2


10.4 VOL % WATER

46




50% LOAD




lB 1BRPM 3B-FT BHP HR BHP-HR BMEP

1400 188 50 23.1 0.461 60.8

1600 200 60 27.5 0.451 64.7

1800 215 73 33.7 0.457 69.5

2000 214 81 38.7 0.475 69.2

2200 205 85 41.4 0.481 66.3

2400 200 91 46.9 0.513 64.7

2600 186 92 51.2 0.556 60.1

2895

FRDF CONTENT:

78 VOL % DF2


10.4 VOL % WATER

47




25% LOAD




1B IBRPM lB-FT BHP HR BHP-HR BMEP

1400 96 25 13.5 0.526 31.0

1600 101 30 15.8 0.514 32.6

1800 106 36 19.5 0.537 34.3

2000 107 40 23.6 0.579 34.6

2200 103 43 26.4 0.611 33.3

2400 100 45 30.4 0.665 32.3

2600 95 46 33.2 0.706 30.7

2895

FRDF CONTENT:

78 VOL % DF2


10.4 VOL % WATER

48




100% LOAD

PERFORMANCE TEST DATA WITH FIRE RESISTANT

DIESEL FUEL (FRDF) AFTER 100 HOURS OF 2.NDURANCE

TESTS WITH THE SAME FRDF



1B LBRPM LB-FT BHP W- BHP-HR BMEP

1400 378 100 44.2 0.438 122.3

1600 402 122 53.1 0.433 130.0

1800 431 147 63.7 0.431 139.4

2000 438 166 72.7 0.436 141.7

2200 419 175 78.8 0.448 135.5

2400 391 178 83.9 0.469 126.5

2600 365 180 89.5 0.495 118.1

2895

FRDF CONTENT:

78 VOL % DF2

10.2 VOL % SURFACTANT (EM1ULSIFIER)

11.3 VOL % WATER

49

Table 5-30. Performance Test Data (100%, FRDF, 200-Hour)



100% LOAD


DIESEL FUEL (FRDF) AFTER 200 HOURS OF MNDURANCE




1B LBRPM LB-FT BHP HR BHP-HR BMEP

1400 360 95 43.3 0.452 116.4

1600 382 117 51.9 0.446 123.6

1800 407 139 61.7 0.442 131.7

2000 415 158 70.3 0.444 134.2

2200 401 167 77.3 0.460 129.7

2400 382 174 83.5 0.478 123.6

2600 358 177 89.1 0.503 115.8

2895

FRDF CONTENT:

78 VOL % DF2

10.2 VOL % SURFACTANT (E•MULSIFIER)

11.8 VOL % WATER

50




100% LOAD


DIESEL FUEL (FRDF) AFTER 300 HOURS OF ENDURANCE




1B LBRPM LB-FT BHP HR BHP-HR

1400 369 98 44.7 0.454

1600 397 121 53.3 0.440

1800 423 144 62.9 0.436

2000 427 162 72.1 0.443

2200 412 172 78.5 0.455

2400 390 178 84.5 0.474

2600 356 176 89.5 0.507

2895

FRDF CONTENT:

78 VOL % DF2

10 VOL % SURFACTANT (E4ULSIFIER)

12 VOL % WATER

51




100% LOAD






lB LBRPM LB-FT BHP HR BHP-HR BMEP

1400 376 100 44.0 0.438 121.6

1600 403 122 53.2 0.433 130.4

1800 423 144 62.8 0.433 136.8

2000 425 161 71.0 0.438 137.5

2200 409 171 77.6 0.452 132.3

2400 388 177 83.6 0.471 125.5

2600 353 175 89.9 0.513 115.8

2895

FRDF CONTENT:

78 VOL % DF2

10 VOL % SURFACTANT (E4ULSIFIER)

12 VOL % WATER

52"




85% LOAD






LBRPM LB-FT BHP LB-HR BHP-HR BMEP

1400 327 87 37.7 0.432 105.8

1600 346 105 45.5 0.431 111.9

1800 365 125 54.2 0.433 118.1

2000 366 139 62.0 0.444 118.4

2200 349 150 67.5 0.450 112.9

2400 339 154 74.4 0.480 109.6

2600 316 156 80.6 0.515 102.2

2895

FRDF CONTENT:

78 , VOL % DF2

10 VOL % SURFACTANT (EMULSIFIER)

12 VOL % WATER

53




70.% LOAD







1400 268 71 31.9 0.446 86.7

1600 285 86 38.1 0.438 92.2

1800 298 102 45.6 0.443 97.0

2000 299 114 52.1 0.456 97.0

2200 291 122 56.8 0.472 92.8

2400 279 127 63.0 0.494 90.2

2600 260 128 68.8 0.537 84.1

2895

FRDF CONTENT:

78 VOL % DF2

10 VOL % SURFACTANT (EMULSIFIER)

12 VOL % WATER

54




50% LOAD






1B LB

RPM LB-FT BHP - R BHP-HR BMEP

1400 193 51 24.3 0.472 62.4

1600 204 62 29,2 0.469 66.0

1800 214 73 34.5 0.470 69.2

2000 215 81 39.5 0.482 69.5

2200 210 88 43.3 0.492 66.3

2400 200 91 49.3 0.539 64.7

2600 185 92 53.7 0.586 59.8

2895

FRDF CONTENT:

78 VOL % DF2

10 VOL % SURFACTANT (EIMULSIFIER)

12 VOL % WATER

55




25% LOAD


DIESEL FUEL (FRDF) AFTER 400 HOURS OF F!NDURANCE




1B

RPM LB-FT BHP HR BHP-HR BMEP

1400 94 25 14.7 0.574 31.0

1600 102 31 18.5 0.595 33.0

1800 105 36 21.7 0.591 34.6

2000 105 40 25.3 0.620 34.6

2200 103 43 28.3 0.655 33.3

2400 100 46 31.7 0.689 32.0

2600 93 46 36.0 0.782 30.0

2895

FRDF CONTENT:

78- VOL % DF2

10 VOL % SURFACTANT (EtMULSIFIER)

12 VOL % WATER

56




100% LOAD

PERFORMANCE TEST DATA WITH DIESEL FUEL (DF2)

AFTER 400 HOURS OF ENDURANCE TESTS WITH FRDF



1B LBRPM LB-FT BHP HU BHP-HR BMEP

1400 457 121 45 0.369 147.8

1600 495 150 54.6 0.361 160.1

1800 509 174 62.3 03.58 164.7

2000 489 186 66.7 0.358 158.2

2200 464 194 72.0 0.370- 150.1

2400 438 200 77.9 0.389 141.7

2600 408 202 83.6 0.414 130.4

2895

57




85% LOAD






1400 387 103 37.0 0.359 125.5

1600 417 127 45.7 0.358 135.5

1800 438 150 53.6 0.356 142.0

2000 420 160 58.1 0.361 136.5

2200 399 167 61.5 0.376 126.2

2400 379 173 68.6 0.395 122.9

2600 358 177 73.9 0.415 116.1

2895 36 19 25.8 1.302 11.6

58




70% LOAD






1400 318 84 30.4 0.358 102.9

1600 345 105 37.2 0.353 111.6

1800 360 123 44.5 0.360 116.4

2000 347 132 48.4 0.366 112.2

2200 331 139 51.9 0.374 103.8

2400 313 142 58.0 0.402 101.2

2600 296 146 62.6 0.427 95.7

2895

59




50% LOAD


AFTER 400 HOURS OF EN4DURANCE TESTS WITH FRDF




1400 226 60 22.1 0.368 73.1

1600 246 75 28.0 0.373 79.6

1800 258 88 32.8 0.371 83.4

2000 247 94 36.1 0.383 79.9

2200 237 99 39.0 0.394 73.7

2400 222 101 43.6 0.429 71.8

2600 211 104 48.2 0.461 68.2

2895

60




25% LOAD






1400 113 30 13.2 0.438 36.5

1600 124 37 16.5 0.436 40.1

1800 128 43 19.39 0.451 41.4

2000 124 47 22.2 0.470 40.1

2200 117 49 24.3 0.496 37.2

2400 112 51 28.15 0.552 36.2

2600 105 52 31.2 0.611 33.9

2895

61




100% LOAD

PERFORMANCE TEST DATA WITH LOWER WATER PERCENTAGE

IN FRDF




1400 408 108 44.3 .407

1600 437 133 54.0 .405

1800 463 158 63.9 .402

2000 453 172 70.6 .409

2200 432 180 76.3 .421

2400 411 187 83.3 .443

2600 382 189 87.6 .463

2888 37 20 28 1.415

FRDF CONTENT:

- 78 VOL % DF2


10.2 vOL % WATER

62




50% LOAD

PERFORMANCE TEST DATA WITH LOWER WATER PERCENTAGE

IN FRDF



1B LBRPM LB-FT BHP HP BHP-HR

1400 191 50 23.2 .455

1600 204 62 28.1 .452

1800 212 73 33.2 .450

2000 213 81 37.1 .458

2200 209 88 41.5 .483

2400 200 91 46.4 .507

2600 185 92 50.6 .552

2888

FRDF CONTENT:

78 - VOL % DF2


10.2 VOL % WATER

63

Table 5-44. Performance Test Data (Lubricating Oil Consumption)

DT-466 NAVISTAR DIESEL ENGINE

ENGINE LUBRICATING OIL CONSUMPTION RATE DURING 400 HOUR ENDURANCE

TEST WITH FIRE RESISTANT DIESEL FUEL (FRDF)

ENDURANCE OUAITITY CUMULATIVE OIL CONSUMPTIONDATE TEST HOURS ADDED, LBS OIL CONSUMPTION, RATE,LB/HR

LBS

8 -l-86 0 0 0 030 2.00 2.00 0.06650 2.25 4.25 0.08570 1.50 5.75 0.082

9-17-86 100 2.25 8.00 0.080150 3.50 11.50 0.076180 1.50 13.00 0.072190 2.00 15.00 0.079

9-29-86 200 2.25 17.25 0.086220 2.50 19.75 0.089230 2.50 22.25 0.096250 2.50 24.75 0.099260 1.25 26.00 0.100280 2.25 28.25 0.101

10-11-86 300 2.25 30.50 0.1016340 0.50 31.00 0.091360 1.00 32.00 0.088370 1.25 33.25 0.089380 1.75 35.00 0.0921397 1.50 36.50 0.0919

11-4-86 400 2.00 38.50 0.0962

64

Table 5-45. Performance Test Data (at the end of 10-Hour)

DT-466 Navistar Diesel Engine, S/N 176482

Program of 10-Hour Endurance Test with Fire ResistantDiesel Fuel (FRDF)

Performance Data were Printed-out at the End of 10-Hour

Endurance Test

Endurance Test Hours 10

Total Operating Hours 65

% LOAD % RPM LB-FT BHP LB/HR LB/BHP-HR BMEP

0 26 5.5 -- 3.1 -- 1.2IDLE

100 100 372 184 90.6 0.491 120.32600 RATED

0 110 39 21 30.3 1.412 12.6

100 75 421 156 67.8 0.433 136.2

100 60 391 116 50.1 0.431 126.5

70 105 265 138 73.0 0.528 85.7

100 69 422 144 61.9 0.428 136.5MAX T. SPD

50 60 185 54 26.1 0.475 59.8

FRDF CONTENT:

78 VOL% DF2

11.6 VOL% SURFACTANT (EMULSIFIER)

10.4 VOL% WATER

65





Endurance Test




0 26 5 3.1 1.6IDLE

100 100 372 184 90.1 0.488 120.6

2600 RATED

0 110 35 19 30.3 1.572 11.3

100 75 431 159 68.6 0.428 139.4

100 60 397 117 51.1 0.433 128.4

70 105 263 136 75.7 0.562 85.1

100 69 422 144 61.7 0.426 136.5

50 60 185 54 26.4 0.480 59.8

FRDF CONTENT:

78 VOL% DF2

11.6VOL% SURFACTANT (EMULSIFIER)

10.4VOL% WATER

66




Performance Data were Printed-out at the End of 30-HourEndurance Test




0 26 4.5 -- 3.4 -- 1.1IDLE

100 100 365 180 91.0 0.502 118.1

2600 RATED

0 110 35 19 30.5 1.583 11.3

100 75 423 156 68.1 0.434 136.8

100 60 397 117 50.8 0.430 128.4

70 105 251 130 70.7 0.540 81.2

100 69 434 148 63.5 0.426 140.4

50 60 188 55 25.9 0.464 60.8

FRDF CONTENT:

78 VOL% DF2


11.6 VOL% WATER

67








0 26 3 -- 3.9 -- 0.9IDLE

100 100 371 183 90.6 0.492 120.0

2600 RATED

0 110 36 19 30.3 1.531 11.6

100 75 426 158 68.25 0.432 137.8

100 60 397 117 50.3 0.426 128.4

70 105 260 135 72.0 0.531 84.1

100 69 420 143 61.6 0.428 135.9

50 60 188 55 23.65 0.430 60.8

FRDF CONTENT:

78 VOL% DF2


10.4 VOL% WATER

68








0 26 7 -- 3.4 -- 2.2IDLE

100 100 373 184 90.3 0.490 120.7

2600 RATED

0 110 39 21 30.1 1.433 12.6

100 75 438 162 70.0 0.430 141.7

100 60 398 118 50.9 0.430 128.7

70 105 264 137 71.9 0.522 85.4

100 69 409 140 60.5 0.431 132.3

50 60 184 55 25.6 0.47 59.8

FRDF CONTENT:

78 VOL% DF2


10.4 VOL% WATER

69




Performance Data were Printed-out at the End of 60 HourEndurance Test




0 26 8 3.7 2.5IDLE

100 100 343 169 84.0 0.494 110.9

2600 RATED

0 110 36 19 30.4 1.535 11.6

100 75 315 116 52.3 0.447 101.9

100 60 403 119 51.3 0.428 130.4

70 105 271 140 74.1 0.526 87.6

100 69 436 149 63.8 0.427 141.0

50 60 183 53 25.5 0.43 60.1

FRDF CONTENT:

78 VOL% DF2


13.2 VOL% WATER

70








0 26 3 3.1 0.9IDLE

100 100 368 182 90.2 0.495 119.0

2600 RATED

0 110 35 19 30.5 1.583 11.3

100 75 441 163 70.6 0.431 142.7

100 60 410 121 52.1 0.428 132.6

70 105 252 131 73.5 0.560 81.5

100 69 452 154 65.7 0.424 146.2

50 60 188 55 26.5 0.475 60.8

FRDF CONTENT:

78 VOL% DF2


10.6 VOL% WATER

71





Endurance Test




0 26 3.1IDLE

100 100 368 182 89.8 0.492 119.0

2600 RATED

0 110 35 19 30.6 1.589 11.3

100 75 435 161 69.8 0.432 140.7

100 60 394 116 50.2 0.429 127.4

70 105 261 135 71.28 0.528 84.4

100 69 429 146 63.7 0.433 138.8

50 60 186 54 26.2 0.478 60.1

FRDF CONTENT:

78 VOL% DF2


10.6 VOL% WATER

72








0 26 5 3.4 1.6IDLE

100 100 366 181 90.3 0.498 118.4

2600 RATED

0 110 37 20 30.8 1.513 11.9

100 75 438 162 70.1 0.431 141.7

100 60 398 118 50.6 0.428 128.7

70 105 269 140 71.3 0.509 87.0

100 69 428 146 63.1 0.430 138.4

50 60 185 54 25.6 0.465 59.8

FRDF CONTENT:

78 VOL% DF2


11.3 VOL% WATER

73








0 26 1 3.7 0.3IDLE

100 100 363 179 90.3 0.502 117.4

2600 RATED

0 110 35 19 31.0 1.631 11.3

100 75 438 162 70.4 0.432 141.7

100 60 396 117 50.9 0.433 128.1

70 105 273 141 75.1 0.530 88.3

100 69 437 149 64.4 0.430 141.4

50 60 187 55 26.3 0.475 60.5

FRDF CONTENT:

78 VOL% DF2


11.8 VOL% WATER

74





Endurance Test




0 26 5 3.7 1.6IDLE

100 100 362 179 89.6 0.499 117.1

2600 RATED

0 110 38 20 31.2 1.494 12.2

100 75 423 157 69.1 0.439 136.8

100 60 391 116 50.7 0.436 126.5

70 105 266 137 72.2 0.523 86.0

100 69 424 145 63.3 0.435 137.2

50 60 186 55 26.1 0.472 60.1

FRDF CONTENT:

78 VOL% DF2


11.8 VOL% WATER

75








0 26 5 3.7 1.6IDLE

100 100 361 178 88.46 0.497 116.8

2600 RATED

0 110 36 19 29.5 1.553 11.6

100 75 431 159 69.3 0.433 139.4

100 60 390 115 50.7 0.437 126.2

70 105 266 137 73.9 0.537 86.0

100 69 426 145 63.2 0.433 137.8

50 60 185 54 26.0 0.473 59.8

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (EMULSIFIER)

12 VOL% WATER

76


DT-466 Navistar Diesel Engine, SIN 176482






0 26 7 3.5 2.2IDLE

100 100 363 179 87.1 0.485 117.42600 RATED

0 110 39 21 30.3 1.415 12.6

100 75 420 155 67.9 0.436 135.9

100 60 393 116 50.8 0.435 127.1

70 105 251 130 72.5 0.555 81.2

100 69 429 147 63.6 0.432 138.8

50 60 185 54 26.3 0.479 59.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

77



Progran of 10-hours Endurance Test with Fire ResistantDiesel Fuel (FRDF)

Performance Data were Printed-out at the BId of 140-Hour

Endurance Test




0 26 7 - 3.5 - 2.2IDLE

100 100 363 179 87.4 0.486 117.42600 RATED

0 110 36 19 29.7 1.564 11.6

100 75 427 158 70.1 0.442 138.1

100 60 382 113 50.0 0.440 123.6

70 105 269 139 74.4 0.532 87.0

100 69 424 145 63.6 0.437 137.2

50 60 183 54 26.0 0.478 59.2

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

78



Progran of 10-hours Endurance Test with Fire ResistantDiesel Fuel (FRDF)Performance Data were Printed-out at the End of 150-Hour

Endurance Test



% LOAD % RPM LB-FT BHP EB/HR LB/BHP-HR BMEP

0 26 5 - 3.7 - 1.6IDLE

100 100 359 177 89.4 0.503 116.1

2600 RATED

0 110 29 15 29.5 1.844 9.3

100 75 424- 157 69.2 0.439 137.2

100 60 388 115 50.6 0.438 125.5

70 105 259 134 75.5 0.561 83.8

100 69 420 144 63.3 0.440 136.0

50 60 179 53 25.9 0.487 57.9

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

79




Perfotmance Data were Printed-out at the End of 160-HourEndurance Test




0 26 4 - 3.9 - 1.2IDLE

100 100 357 176 89.5 0.506 115.5

2600 RATED

0 110 40 22 32.0 1.450 12.9

100 75 419 155 68.6 0.440 135.5

100 60 387 114 50.9 0.443 125.2

70 105 260 134 75.3 0.557 84.1

100 69 423 144 63.7 0.439 136.8

50 60 187 55 26.4 0.480 60.5

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

80



Progran of 10-hours Endurance Test with Fire ResistantDiesel Fuel (FRDF)Performance Data were Printed-out at the End of 170-Hour

Endurance Test




0 26 4 - 3.9 - 1.2IDLE

100 100 357 176 89.9 0.508 115.5

2600 RATED

0 110 38 20 32.2 1.538 12.2

100 75 427 158 70.3 0.443 138.1

100 60 382 113 50.3 0.443 123.6

70 105 267 139 74.1 0.532 86.4

100 69 415 141 63.3 0.445 134.2

50 60 185 54 26.8 0.487 59.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

81



Program of 10-hours Endurance Test with Fire ResistantDiesel Fuel (FRDF)

Performance Data were Printed-out at the aid of 180-HourEndurance Test




0 26 5 - 3.6 - 1.6IDLE

100 100 356 176 89.7 0.509 115.22600 RATED

0 110 35 19 31.4 1.625 11.5

100 75 425 157 70.2 0.445 137.5

100 60 386 114 50.5 0.440 124.9

70 105 262 135 74.4 0.547 84.7

100 69 421 144 63.5 0.440 136.2

50 60 186 55 26.5 0.474 60.1

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

82








0 26 4 - 3.7 - 1.2IDLE

100 100 356 176 89.6 0.508 115.22600 RATED

0 110 36 19 31.7 1.599 11.6

100 75 428 158 70.2 0.441 138.4

100 60 384 113 50.6 0.443 124.2

70 105 248 128 74.1 0.575 80.2

100 69 421 144 63.5 0.439 136.2

50 60 183 54 26.8 0.493 59.2

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (EIMULSIFIER)

12 VOL% WATER

83





Endurance Test




0 26 3 - 3.4 - 0.9IDLE

100 100 357 176 89.6 0.506 115.5

2600 RATED

0- 110 40 21 30.8 1.469 12.9

100 75 415 154 68.2 0.442 134.2

100 60 379 112 49.6 0.440 122.6

70 105 260 135 74.5 0.551 84.1

100 69 407 139 62.6 0.447 131.7

50 60 184 54 26.9 0.491 59.5

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

84







% LOAD % RPM tB-FT BHP LB/HR LB/BHP-HR BMEP

0 26 - - 3.0 -IDLE

100 100 354 175 89.6 0.511 114.52600 RATED

0 110 33 18 31.3 1.724 10.6

100 75 423 156 69.4 0.442 136.8

100 60 387 114 50.9 0.443 125.2

70 105 259 134 74.3 0.551 83.8

100 69 427 146 64.4 0.440 138.1

50 60 185 54 27.1 0.492 59.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

85








0 26 - - 3.1 -

IDLE

100 100 356 176 89.8 0.509 115.2

2600 RATED

0 110 34 18 32.1 1.711 11.0

100 75 427 158 70.0 0.441 138.1

100 60 391 116 51.3 0.441 126.5

70 105 259 134 74.5 0.552 83.8

100 69 423 144 66.9 0.441 136.8

50 60 186 55 27.1 0.493 60.1

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

86








0 26 - - 3.8 - -IDLE

100 100 356 176 89.8 0.509 115.22600 RATED

0 110 39 21 32.3 1.503 12.6

100 75 429 159 69.9 0.439 138.8

100 60 399 118 51.6 0.435 129.1

70 105 261 135 74.7 0.551 84.4

100 69 434 148 64.7 0.434 140.4

50 60 189 56 27.5 0.489 61.1

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

87





Endurance Test




0 26 - - 3.4 -

IDLE

100 100 359 177 89.3 0.502 116.1

2600 RATED

0 110 37 20 31.8 1.562 11.9

100 75 426 158 69.2 0.437 137.8

100 60 393 116 51.0 0.436 127.1

70 105 261 135 74.4 0.549 84.4

100 69 433 148 64.5 0.434 140.1

50 60 184 54 26.7 0.488 59.5

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

88








0 26 - - - -

IDLE

100 100 359 177 89.3 0.502 116.1

2600 RATED

0 110 38 20 32.1 1.534 12.2

100 75 429 159 69.6 0.437 138.8

100 60 401 119 51.7 0.433 129.7

70 105 250 130 71.4 0.548 80.8

100 69 435 149 64.6 0.433 140.7

50 60 186 55 26.8 0.484 60.1

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

89








0 26 - - - -

IDLE

100 100 352 174 89.5 0.513 113.9

2600 RATED

0 110 37 20 31.8 1.567 11.9

100 75 408 151 68.2 0.449 132.0

100 60 387 115 50.4 0.438 125.2

70 105 260 134 72.4 0.539 84.1

100 69 408 139 61.9 0.442 132.0

50 60 172 51 25.8 0.505 55.6

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

90





Endurance Test




0 26 - - - -

IDLE

100 100 355 175 89.0 0.506 114.82600 RATED

0 110 38 21 30.4 1.447 12.0

100 75 421 156 68.8 0.439 136.2

100 60 393 116 50.3 0.433 127.1

70 105 261, 135 73.6 0.544 84.4

100 69 428 146 63.6 0.433 138.4

50 60 185 54 26.6 0.484 59.8

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (FIULSIFIER)

12 VOL% WATER

91

Table 5-72. Performance Test Data(at the end of 280-Hour)

IDT-466 Navistar Diesel Engine, S/N 176482


Performance Data were Printed-out at the Eknd of 280-HourEndurance Test



LOAD % RPM LB-FT BHP LB/HR LB/BHP-HR BMEP

0 26 - - - -

IDLE

100 100 358 177 89.0 0.502 115.82600 RATED

0 110 37 20 31.3 1.560 11.9

100 75 416 154 68.1 0.441 134.6

100 60 393 116 51.1 0.437 127.1

70 105 257 132 74.3 0.559 83.1

100 69 421 144 63.3 0.438 136.2

50 60 185 54 27.0 0.745 59.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

92








0 26 ..- - -

IDLE

100 100 359 177 89.9 0.505 116.1

2600 RATED

0 110 33 18 32.0 1.768 10.6

100 75 423 157 69.4 0.441 136.8

100 60 387 114 50.4 0.439 125.2

70 105 260 134 74.6 0.555 84.1

100 69 418 143 61.5 0.429 135.2

50 60 185 54 27.2 0.494 59.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

93



Program of 10-hours Endurance Test with Fire ResistantDiesel Fuel (FRDF)Performance Data were Printed-out at the End of 300-Hour

Endurance Test




0 26 - - - -

IDLE

100 100 351 173 88.3 0.507 113.52600 RATED

0 110 35 19 31.5 1.640 11.3

100 75 398 147 66.5 0.450 128.7

100 60 384 113 50.0 0.438 124.2

70 105 259 133 75.2 0.562 83.8

100 69 405 138 60.9 0.439 131.0

50 60 178 52 26.6 0.502 57.6

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (EM1ULSIFIER)

12 VOL% WATER

94


DT-466 Navistar Diesel M~gine, S/N 176482





% LOAD % RPM LB-FT BHP LB/HR EB/BHP-HR BMEP

0 26 .- - -

IDLE

100 100 356 176 89.6 0.5082600 RATED

0 110 30 16 30.9 1.875

100 75 427 158 69.8 0.440

100 60 392 116 50.6 0.434

70 105 256 132 72.2 Q.544

100 69 409 140 60.8 0.434

50 60 181 54 26.0 0.481

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (E•MULSIFIER)

12 VOL% WATER

95





Endurance Test


Total operating Hours 384


0 26 - - - -

IDLE

100 100 352 174 88.6 0.508 113.9

2600 RATED

0 110 32 17 30.2 1.744 10.3

100 75 417 154 68.3 0.441 134.9

100 60 385 114 50.6 0.442 124.5

70 105 248 128 71.3 0.555 80.2

100 69 415 142 62.4 0.439 134.2

50 60 180 53 26.5 0.495 58.2

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (EM4ULSIFIER)

12 VOL% WATER

96




Perfonnance Data were Printed-out at the End of 330-HourEndurance Test




0 26 - - - -

IDLE

100 100 354 175 88.8 0.506 114.5

2600 RATED

0 110 30 16 30.5 1.854 9.7

100 75 421 156 68.8 0.439 136.2

100 60 387 114 50.7 0.441 125.2

70 105 266 137 74.2 0.540 86.0

100 69 415 142 62.6 0.440 134.2

50 60 183 54 26.4 0.485 59.2

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

97




Performance Data were Printed-out at the aid of 340-HourEndurance Test




0 26 - - - -

IDLE

100 100 354 175 88.9 0.507 114.52600 RATED

0 110 35 19 30.9 1.611 11.3

100 75 419 155 68.8 0.442 135.5

100 60 411 152 68.1 0.446 132.9

70 105 262 135 75.6 0.559 84.7

100 69 424 145 63.2 0.435 137.2

50 60 186 55 26.9 0.486 60.1

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

98








0 26 2 - 2.8 - 0.6IDLE

100 100 356 176 88.6 0.502 115.22600 RATED

0 110 30 16 31.0 1.937 9.7

100 75 426 158 69.7 0.440 137.8

100 60 391 116 50.8 0.437 126.5

70 105 259 133 74.6 0.557 83.8

100 69 424 145 63.5 0.436 137.2

50 60 182 54 26.8 0.495 58.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

99





Endurance Test




0 26 - - 4 -IDLE

100 100 354 175 89.0 .508 114.5

2600 RATED

0 110 29 15 30.2 1.895 9.3

100 75 425 157 69.5 0.440 137.5

100 60 388 115 50.6 0.439 125.5

70 105 267 137 74.6 0.545 86.4

100 69 417 142 62.3 0.438 134.9

50 60 187 55 27.7 0.498 60.5

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

100








0 26 - - 3.9 - __IDLE

100 100 353 174 88.2 .504 114.22600 RATED

0 110 35 19 30.8 1.604 11.3

100 75 417 154 67.8 0.438 134.9

100 60 390 115 50.0 0.431 126.2

70 105 259 133 74.0 0.557 83.8

100 69 418 143 66.0 0.432 135.2

50 60 168 49 45.2 0.508 54.3

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (E4MULSIFIER)

12 VOL% WATER

101

Table 5-82. Performance Test Data (at the end of 3 8 0-Hour)







0 26 - - 3.5 --IDLE

100 100 358 177 88.0 .496 115.8

2600 RATED

0 110 35 19 30.6 1.593 11.3

100 75 426 158 68.8 0.434 137.8

100 60 396 117 50.7 0.430 128.1

70 105 263 135 73.9 0.544 85.1

100 69 422 144 62.0 0.428 136.5

50 60 172 51 25.0 0.489 55.6

FRDF CONTENT:

78 VOL% DF2

10 VOL% SURFACTANT (EMIULSIFIER)

12 VOL% WATER

102







% LOAD % RPM LB-FT BHP LB/HR EB/BHP-HR BMEP

0 26 -- - 4.0 - -

IDLE

100 100 353 174 88.5 .506 114.2

2600 RATED

'0 110 36 19 30.7 1.615 11.6

100 75 416 154 68.0 0.440 134.6

100 60 387 115 50.5 0.439 125.2

70 105 246 127 72.6 0.569 79.6

100 69 426 145 62.7 0.432 137.8

50 60 185 54 26.6 0.484 59.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

NOTE: DELIVERY VALVE GASKET OF THE FUEL INJECTION PUMP FAILED AT 388DURABILITY TEST HOUR

103








0 26 -- - 3.5 - -

IDLE

100 100 356 176 89.0 .505 115.2

2600 RATED

0 110 34 18 30.0 1.661 11.0

100 75 432 160 70.6 0.440 139.7

100 60 393 116 50.8 0.438 127.1

70 105 258 133 73.3 0.551 83.4

100 69 431 147 63.7 0.433 139.4

50 60 188 55 26.7 0.485 60.8

FRDF CONTENT:

78 VOL% DF2


12 VOL% WATER

104

Table 5-85. Properties of Reference Diesel Fuels

Property No. 7225 No. 8821

Fed. Spec.Specification Type MIL-F-46162A(MR)-II VV-F-800b-DF-2Gravity, *API at 15.56C 36.1 35.2Density, g/mL at 15.5*C 0.844 0.848Flash Point, PMCC, *C(QF) 60 (140) 72 (161)Fire Point, °C(OF) 91 (196) 84 (183)Cloud Point, *C(*F) -21 (-6) -1 (30)Pour Point, °C(*F) -24 (-11) -10 (14)Kinematic Viscosity, cSt at 400C 2.2 3.2Accelerated Stability

(ASTM D 2274), mg/100 mL 0.6 2.7Total Acid No., mg KOH/g 0.01 0.03Steam Jet Gum, mg/100 mL 3.9 3.2Sulfur, wt% 0.35 0.47Copper Strip Corrosion

(ASTM D 130) 1A 1ACarbon, wt% 86.8 86.7Hydrogen, wt% 13.2 13.3Heat of Combustion (Gross), J/kg 45.1 x 106 45.7 x 10

(Btu/lb) (19,427) 6 (19,670)Heat of Combustion (Net), J/kg 42.5 x 10 42.8 x 10

(Btu/l b) (18,283) (18,450)Hydrocarbon Types,

FIA, vol% saturates -- 69.1aromatics - 29.4

Hydrocarbon Types,HPLC, wt% saturates 72.5 74.1

aromatics 27.5 25.9

Aromatic Ring Carbon,UV, wt% mononuclear 7.08 7.50

dinucle~r 11.47 6.54trinuclear 0.31 0.36total 18.86 14.40

Cetane No. 48 51Distillation (ASTM D 86), °C(*F)

Initial Boiling Point 166 (331) 183 (362)10% Distilled 219 (426) 225 (437)50% Distilled 244 (471) 282 (539)90% Distilled 296 (565) 331 (628)End Point 358 (676) 361 (682)

105

100 GALLON/HR

TAPDF2 WATER EQUIPPED WITH

FLUID FLOW CONTROL VALVE

DF2 TAP SURFACTANT SUPPLYBARREL WATER SURFACTANT

BAREL BARREL BARRELS

ON-OFF MANUAL SHUT-OFFVALVES

11 /OF2WAE

1 1/2 HP PUMP PUMP SURFACTANT PUMP

ELECTRIC MOTOR220/240 VAC

1 P MMICROMETER DIALS

PRESSURE GAGES35 PSI

MIXERS

FLOW 100 GAL

METER

FRDF TO 300 GAL STORAGE TANK

Figure 5-1. Schematic Flow Diagram of FRDF Blending System

106

Figure_5-2. Performance TestDiagram (100% Load, DF2, 0-Hour)

4-4

Z0

010

Figure 5-3. Performance Test Diagram (85% Load, DF2, 0-Hour)

zi

ZO

x

-w

I--I-

-I-4-

108


4+4

03

z~Ln

ou ý

I-JD

------- -

109


MM

1-j

zw

zd

4.'

110

*Figure 5-6. Performance Test Diagram (25% LoadDFý2., 0-Hour)

cv,

U-.

owo-U.+ý

I'.

L61

Figure 5-7. Performance Test Diagram (100% Load. FRDF. 0Hour)

-4j

0.1

II.T

112

1A

..... ...

COJ

-4i

~Z0

u u

in'

2.i

(113

Figure 5-9. Performance Test Diagram (70% Load, FRDF, 0-Hour)

KE>

040

'-4V

114


44

7-1

U p ,

Z.o

U)

xU

1,

XIL-

I'.

115


#=C

9-M-

-- w

UU-

116L

Figure.5-12. Performance Test Diagram (100% Load, FRDF, 1-00-.Rour)

IT Ii I I~

I . . . .Ii [ IN. .. : I ; ; :

I k P l } ] l I T I 1 [ 1 I I Ii r L L f • I 1 [ : ! : • • I i : l ~ i ! : : f i l [ ' ;! [,T 1

: ti~ ~~~ ~ ~ 141t • I ' l: i i l !IIT 11 ; , 1l iiýll lll 1 ii+ f rI iI : 1 ; ! l t l i l I l i • l l l ~ ; ; ; •:

i i~ i. . .. .. ... .. I i

,I T i

I T , i i . . . . .. . . .... . . .~ ~~~~~~. . . .. .+ i T T: •• ' I ! ' ' : , : F

,~~~H i :i,

i:! .. ..........-r I F• i • . . . . . . . . ' ' : I . . . i I . . .. . : ! : ii - - -

91• : • • ' al i L.1i i ' , • . . { ~ ~ : ' l•+ ! i i i i i . ; ' i i ' • ' i i ' : ; ! • • l ; , . .. • -

S. . . : . .. +• 1: ' l il i ,: , l'~ l ' ~ i i ': : 1 1 7. ..

Figure_5_-13._P~e~rformance Test Diagram (100% Load, FRDF, 200-Hour)

(Nt=

I T4T

fad

0A:

-TI

118O

Figure 5-14. Performance.Test Diagram (100% Load, FRDF, 300-Hour)

CY.JC14

ZIA

MID

I--II.-.

119

Figure 5-15. Performance Test Data (100% Load, FRDF, 4 00-Hour)

"M.

0-

I . I

10

4~.

120


C"q

.DO

.( J ..... ...mi l

z+

-wj

oww

M.

9u

121


I. T

ZOUU

04

k9

I-122

Figure 5-18. Performance Test Diagram (50% Load, FRflF, 400-Hour)

-4++

~Hi

(jEE

T i l , Iqwp - 1 '

U_-

I--I

H - .. . .

owt

Hi

0.1 2 -

Figure 5-19. Performance Test Diagrýam (25%_Load, FRDF, 400-Hourr

04

;L6

124


CY)

Cf,

-t

ITIw

0

166

I-IT�

1 : p

4'T

125.


U U

04

126


FF 1 1 1 T l

"I 1 . il

1 1 1 T T I

IN

I p I i TiIT

.... ...

Up,

127

Figure 5-23. Performance Test Diagram (50% Load, DF2, 400 -Hour)

;pp

-- 4

'-IT

. .. . . . .

I T

HH '',44128

Figure 5-24. Performance Test Diagram (25%," DF2, 40-0-Hour)-

-14

. . .. .

T- I I I I

-4w

'+44

I T-1 1

U.i

129I

Figure 5-25. Performance Test Diagram (100% Load, FBDF, 400-Hour)

T- II III e

IC 7 1- 1

A U I I I I I I I I I I 1

0 p l

0in

04+ 1

C : I ;1 11 0 i i

I I I i

vi I I30


---7rj(q ej-U- '- I I I I I-, I I I I K 1 1 1 L I I I I 1 0"

I I n 1-4 1 1 11 1 1 1 Z-I I ilz I I I Od 1 11 1 1 A[ I N1 I I r"I I I I L I 4J I I LrI I T 1 1 ( I- i (( A OP I

I f I I I I I

I 1 1 Z

L-L I I t I I I

I U I I Ix i I I 1 1 1 11

1 74

A II Ix 1, 1I V

IV-

I I f I I Ix IA I

IN I I II I 7-J

i I I I i tI I

r

I I I Aj.

I %A liI I N J I I I I i I I I

I IN

IN I INI I

tu I I XI it

I I

ILI- W: I I I I I I

C3

131

ýFigure.5-27. Performance Test Diagram (HP at 100% Load foir DF2 and FRDF)

C4

Figure 5-28. Performance Test Diagram (SFC at 100% for DF2 and_ FRDF)

1' ;± i 11

+

.4/ý

%LL

i,, T 1 1 33 Il

Figure 5-29, Performance Test Diagram (Torque at 100% Load for DF 2 and FRDF

U",ýE

-- --- ma

3L23

134

Figure 5-30. Performance Test Diagram (HP at 85% Load for DF2 and FPDF)

-,44

I-J-

135

Figure 5-31.. Performance Test Diagram (SFC at 85% Load, for DF2 anc' FRDF)

-------------

'\ ./

&4-

q136

Figure 5-32. Performance Test Diagram (Torque at 85% Load, for DF2 and FRDF)

I HH,

137

Figure 5-33. Performance Test Diagram (HP at 70% Load, for DF2 and FRDF)

C.,0

K>F

U3

- ci 4L-j

138

Figure 5-34. Performance Test Diagram (SFC at 70% Load, for DF2 and FRDF)

'In

139

Figure 5-35. Performance Test Diagram (Torque at 70% Load, for DF2 and FRDF)

IrV

"T" tog•, : i l, L I'. II. .

... .... 4 7 • _' ' "

,I4-

0J • | !I ,!i ,i' • ~ ~ ;; , i'',' ,i• : • -~ • I i • I,.r I I i . . (

Figure 5-36. Performance Test Diagram (HP at 50% Load for DF2 and FRDF)

=141

Figure 53.Performance Test Diagram (SFC at 50% Load for DF2 and FRDF)

3-

kAA

i T-

142

Figure 5-38. Performance Test Diagram (Torque at 50% Load for DF2 and FRDF)

H.-7

z4.

+4

Figure 5-39. Performance Test Diagram (HP at 25% Load for DF2 and FRDF)

1Tý

(C(A

c~a4

144~

Figure 5-40. Performance Test Diagram (SFC at 25% Load for DF2 and FRDF)

114

Figure 5-41. Performance Test Diagram (Torque at 25% Load for DF2 and FRDX

,k.t -E, i a--=-

Q4

YAA __

146

APPENDIX A

ANALYSIS OF FUELS AND LUBRICANTS

A-i

/

BELVOIR FUELS AND LUBRICANTS RESEARCH FACILITY (SwRI)6220 CULEBRA ROAD-P.O.DRAWER 28510 PH:512-6N-5111 SAN ANTONIOTEXAS 7284

BFLRF

File: 02-8341-113

29 3uly 1987

CommanderU.S. Army Belvoir Research, Develop-

ment and Engineering CenterAttn: STRBE-VF, Mr. M.E. LePeraFort Belvoir, Virginia 22060-5606

Subject: Analysis of the Fuels and Lubricants Used in the TACOM FRF Durability Test

Dear Sir:

Enclosed you will find the results of the analysis conducted at Belvoir Fuels andLubricants Research Facility (SwRI) on the fuels and lubricants used in the FRFdurability test. Brief interpretative discussions are also included.

If you have further questions, please do not hesitate to call.

Very truly yours,

S.3. LestzDirector

B.R. WrightManagerSpecial Projects

SJL/BRW/lap (BRWI.N)

Enclosure

cf: U.S. Army Belvoir Research, Development and Engineering Center, Attn:STRBE-VF, Mr. F.W. Schaekel

Commander, U.S. Army Tank-Automotive Command, Propulsion Systems Division,Attn: AMSTA-RGE, Mr. M. Mekari, Warren, MI 48397-5000

A- 3

400-HOUR NATO CYCLE EVALUATION OFFIRE-RESISTANT FUEL (FRF)CONDUCTED AT USATACOM

This report summarizes the results of analysis on the fire-resistant fuel (FRF) that was

utilized in the 400-hour NATO cycle test to evaluate the engine compatibility with the

water-containing fuel. Oil samples taken at 50-hour intervals were also analyzed for

fuel dilution or engine distress related to the use of this special fuel blend.

The concern over the water content of the fuel stemmed from the fact that the

regulation of the in-line blender was difficult to maintain constant. Therefore, if power

loss is being calculated based on water content, precise control of water content was

mandatory.

Fuels

TABLE I summarizes the results of water analysis that was conducted at Belvoir Fuels

and Lubricants Research Facility (BFLRF) at Southwest Research Institute.

TABLE 1. Water Analyses of FRF Samples

AnalysisDate Sample ID WaterContent, vol%

08-29-86 TACOM Blend 07-30-86 10.408-29-86 TACOM Blend 08-25-86 11.609-09-86 57/57/73 13.209-09-86 57170/73 Top of Tank 10.609-09-86 57/70173 Bottom of Tank 11.809-09-86 From Cell 10.809-18-86 09-12-86 57/57/73 11.309-18-86 09-16-86 57/62/74 12.010-06-86 10-03-86 57/62/74 13.212-03-86 Mixer 57/50/74 10.212-03-86 Engine Filter 57/62/73 12.6

It is obvious from the water analysis data that the water content initially blended into

the fuel did not remain constant and that there was some separation/enrichment at

various positions in the fuel-handling system.

A-4

TABLE 2 shows the analysis conducted on the two batches of base fuel that were used

throughout the testing. The fuel used on this program was procured as DF-2.

Specifications for MIL-F-46162B are also included for ready comparison.

Lubricants

Samples of the used lubricant were withdrawn every 50 hours throughout the test

duration. These samples were analyzed for changes that commonly occur during

extended engine test hours. Basically, there were very few changes that could be

identified and none were significant. Unfortunately, samples of the new oil were notavailable to allow direct comparisons; however, since only minimal changes throughout

the test duration were noted, new oil comparisons cannot be considered critical to the

overall assessment of the lubricant analysis. The following tables and graphs show the

tests that were conducted and the results that were obtained. TABLE 3 shows the

results obtained for changes in viscosity, acid and base number. It was not possible to

correlate these numbers with make-up since that information was not available.

Basically, there were no significant changes in viscosity. The acid number and base

number did not show significant changes that would indicate stressing of the oil. Even

though the base number did not indicate a high base number, no major reductions

(showing acid formation) were observed. TABLE 4 shows the metals that were found in

the used oil samples. The iron was low indicating no serious wear problems in cylinder

liners and pistons. The bearing materials (primarily lead and copper) showed no distress

in the highly loaded bearing areas. There was no significant change in additives as shown

in the barium, phosphorous and zinc concentrations.

The next eight graphs are spectrum taken from the infrared analysis of the samples.

There are a number of verifications and indications from reviewing these spectra.

Basically, there did not appear to be heavy soot loading since there was no major

baseline displacement. Moisture or coolant (as diluents) do not appear in the sample and

lubricant oxidation (chemical breakdown) does not appear on the spectrum.

In summary, analyses of the lubricant samples taken every 50 hours do not show any

indications that the engine was being stressed or that contaminants were entering the oil

sump.

A-5

(BRWI.L) 2

TABLE 2. Analysis of DF-2 Test Fuels

MIL-F-46162B ASTM TACOM TACOM

Properties Requirements Test Method 07-29-86 08-21-86

Density, kg/L at 150C Report D 287 0.8489 0.8479

Gravity, °API NR (a) D 287 35.1 35.3

Flash point, 0C Report D 93 75.0 67.2

Distillation, 0C D 86Initial boiling point Report -- --

10% recovered Report50% recovered 245-28590% recovered 330-357 ..

95% recovered 350-375 ....End point 385 max -- --

Sulfur, wt% 0.95-1.05 D 2622 0.22 0.29

Accelerated stability,total insolubles,mg/100 mL 1.5 max D 2274 ....

Cetane index (b) 40-45 D 976 ....

Cetane number (b) 40-45 D 613 -- --

Kinematic viscosity at40 0 C, cSt 1.9-4.1 D 445 2.35 2.47

Cloud point, 0C -13 max D 2500 -25 -18

Pour point, 0C -18 max D 97 -28 -19

Particulate contamination,mg/L (0.8 jim filter) 10 max D 2276 -- --

(Appendix A2)

Volume filtered, L IAsh, wt% 0.02 max D 482 ....

Carbon residue, 10%bottoms, wt% 0.20 max D 524

Neutralization No.mg KOH/g 0.2 max D 974

Copper corrosion at500C 1 max D 130 -- --

Net heat of combustion,Btu/lb Report D 240 18313 18283

Aromatics, vol% Report D 1319 -- --

Carbon, % 86.86 86.85

Hydrogen, % 12.99 13.04

(a) NR = No Requirement.(b) ND = Not Determined.

A-6

(BRWI.L) 3

TABLE 3. Used Oil Analysis

Kinematic KinematicViscosity Viscosity

Samples at 40 0 C at 100 0 C Vi TAN TBN

50 hrs 95.87 cSt 12.72 cSt 129 3.49 4.53

100 hrs 101.70 cSt 13.53 cSt 133 3.60 4.34

150 hrs 103.84 cSt 13.37 cSt 127 3.22 4.02

200 hrs 110.44 cSt 13.83 cSt 125 3.35 3.43

250 hrs 108.62 cSt 13.75 cSt 126 3.13 4.40

300 hrs 115.21 cSt 14.53 cSt 128 3.48 3.71

350 hrs 108.90 cSt 13.70 cSt 125 2.99 4.01

400 hrs 112.98 cSt 14.38 cSt 129 3.11 3.48

A- 7

(BRWI.L) 4

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APPENDIX B

NATO STANDARD DIESEL AND SPARK IGNITION ENGINE LAB TEST SPECIFICATIONS

B-i

7L NATO UNCLASSIFIED

(

I

.PART II

(, NATO STANDARD DIESEL AND SPARK

IGNITION ENGINES LABORATORY TEST

-- ==OOOOO==--

AEP-5

JUNE 80 ISSUE

JAN 84 REVISED

=oOOO==--

-21-

B-3

& ii

S:-22

NATO UNCLASSIFIEDCHAPTER I

GENERAL - DEFINITIONS

SECTION 1-i GENERAL

The purpose of this document is to define a test methodand standard conditions to enable all NATO countries toconduct tests using an identical method or to analyzethe tests conducted in the laboratories of other NATOcountries on the basis of this method.

The method described below is independent of existingnational test methods, which may be used for supplemen-tary testing.

When an engine has met the requirements of the tests un-der the present code, its power rating should be indica-

Sted as follow Rated Power ... kW (... metric HP) at... r.p.m., in accordance with NATO AEP 5 - june 80issue.

B-4

-22-

V S- - 23-

- SECTION 1-2 - FIELD OF APPLICATION

These test requirements are applicable to all militaryvehicles fitted with Diesel or Spark ignition engines.

I Pr

I

B-5

- 23 -

SECTION 1-3 - DEFINITIONS

A major failure is a failure of any part or componentof the engine assembly that leads to a final stoppageof the engine or that brings about a loss of powerwhich cannot be rectified to give at least 95 % of ra-ted power, within the scope of normal maintenance andadj ustement.

Any major failure will lead to termination of the testand any retest must 'start at 0 hour.

Major failures and corrective action are to be reportedto the proper National Authority.

A minor failure is a failure which leads to a loss ofpower or degradation of the operation of the engine andwhich it is possible to remedy within the scope of nor-mal maintenance and adjustment. If 95 % of the rated po-wer cannot be obtained after normal maintenance thenthe test will be terminated.

Pr

The minor failures and the measures taken to overcomethemn must be included in the report.

( The suitability of an engine for NATO AEP 5 is to bethe responsibility of the National Authorities aftercompletion of the 400 hours test and consideration ofthe final condition of the engine.

NOTE : The measurement units must are to be in accordance withthe Syst~me International

B-6

-24-

CHAPTER 2

C TEST REQUIREMENTS

SECTION 2-1 - GENERAL COMPOSITION AND ORDER OF TEST

2.1.1. Engine reception.

Running-in in accordance with manufacturer's instruc-tions.

Performance test, complete (full and part loads).

I Endurance test.

Performance test, complete (full and part loads).

Disassembly, inspection and measurement.,

Report.

K NOTES (1) Engine measurements may be carried out before run-ning-in.

(2) The manufacturer is responsible for defining therunning-in program and the engine should have beenrun-in before it is submitted for testing.

(3) In so far as possible, the manufacturer's drawingand technical data will be supplied with the engine, toassist inspection and measurement of components.

(4) It is normal practice for the engine to be given apreliminary performance test immediatly after receipt,to check acceptability.

(5) If an initial inspection is accomplished, the finalone should be carried out by the same inspection teamusing the same gauges.

K B-7

-25-

- "-.-=,~C ~ -s

2.1.2. During performance and durability testing, the follo-wing variables will be monitored :

a - Main valuesSpeed (engine output shaft)Torque (engine output shaft)

b - Ambient conditionsTemperature of ambient airAtmospheric pressureHumidity

c - Air and gasesInlet air temperatureInlet or cylinder inlet depressionInlet air flow (performance test only)Air temperature and pressure in the inlet manifoldExhaust temperatureExhaust back pressure

d - Lubrication and coolinc

Oil temperatures and pressures

Temp;ratures into and out of external coolersFlow rates of fluids to cooling devices external to

the engine (for heat rejection calculations). Per-formance test onlyOil consumption (during endurance tests only)

e - FuelFuel temperature

I Fuel consumption

1 - MiscellaneousBlow-bySmoke density

B-8

-26-

I -. 2 2.1.3. • REGJLATED PARAMETERS

Outlet temperature of cooling agent

a - water + antifreeze = 96*C + 3*Cb - other cooling agents = to manufacturers specifica-ti ons

Inlet Air Depression (*) at rated power :-25 + 5 mbarExhaust Back Pressure (**) at rated power T0 + 5 mbar

Fuel temperature at injection pump inlet 300 C + 3"C

Inlet air temperature : The inlet temperature will bemaintained as close as possible to 25*C.

(*) Depression between static atmosphere and total pres-.sure at the point of measurement.

(**) Exhaust back pressure between static atmosphericand static pressure at the point of measurement. Forsmall engines, which are sensitive to exhaust back pres-sure manufacturers' recommended figures should be used

2.1.4. TEST CONDITI0NS

Measuring is to be done in normal "and stable.operating"conditions.

The temperature of the air entering the engine (ambientair) is to be measured at a maximum distance of 0,15 mfrom the air filter inlet or, if there is no filter,0,15 m from the air inlet nozzle. The thermometer orthermocouple must be protected against heat radiationand be located directly in the air jet. Testing must becarried out in an adequate number of positions to givea representative inlet temperature.

Once an output speed has been selected for measurementpurposes, its value must not vary by more than + 1 % or+ 10 r.p.m. (whichever of these limits is the higher)during measurement.

The readings for brake load, fuel consumption and inletair temperature are to be taken simultaneously, the va-lue recorded being the average of two stabilized re-sults, obtained in succession with brake load and fuel

( consumption differing by less than 2 %.

- 27-

B-9

-28-

When a device fitted with an automatic starting systemis used for measuring speed and fuel consumption, theduration of measurement must be at least 30 seconds ;

Sif the measuring device is manually operated, the dura-tion must be at least 60 seconds.

An instantaneous consumption measuring device may beutilised.

The exhaust gas outlet temperature must be measured ata point downstream and less than 100 mm from the flan-ge(s) of the exhaust manifold(s).

Lubricant temperature is to be measured at the inletand outlet of the heat exchanger if there is one. Other-wise it must be taken preferably in the lubrication sys-tem, or, failing this, in the crank case. The measuringpoint will be specified in the test report.

Fuel temperature must be read at the injection pumpinlet, or carburattor inlet.

4"t• Auxiliary power take-offs may be loaded and then measu-

red.

2.1.5. FUELS - LUBRICANTS AND ANTI FREEZES

Engines are to be tested on fuels, lubricants and anti-freezes as specified by the relevant NATO Authorities.

JV

. 4

SB- 10

-28-

*

"* 2 .1.6. • MEASU REMENT ACCU RACY

-TORQUEK

The torque must be accurate within + 0,5 % of thehighest value to be measured.

* - OUTPUT SPEED

Measurement must be accurate to within + 0,5 %.

- FUEL CONSUMPTION

+ 1 % for all apparutus used.

- TEMPERATURES

Intake air + 1*C.

- PRESS URE

Atmospheric pressure + 0,7 mbarAir and gas pressure + 50 mbar"Inductiont and exhaust pressure and depression + 0,250Pressure of other fluids + 250 mbar.

j,

B-II

- 29-

I-

-. SECTION 2-2 DEFINITION OF ENGINE

Engines will be equipped only with such auxiliary equip-ment as is strictly essential to their operation (seetable of auxiliary equipment at section 2.6).

;V

1B-12

-30 -

ji .. t ~ I - 31-

SECTION 2-3 - PERFORMANCE TEST

C The performance test maximum load curve will be plottedfran measurements taken at a minimum of five speed set-tings, one of these settings being the rated speed.

For each setting, the engine should be run for a suffi-cient time to allow the operating parameters to stabili-ze.

Part-load data is to recorded at the same pre-selected

* speeds as was used for the full-load test. The part

loads for each speed point are .to be calculated atleast for 85 %, 70 %, 50 % and 25 % of the full load atthe given speed.

During this test, the smoke emission as measured on theRobert BOSCH Scale (or equivalent) shall not exceed 4.5.(Diesel engines only).

No correction factor will be applied and the test re-sults must include air temperature and atmospheric pres-

" ~ sure.

B-13

-31-

- 32-J

SECTION 2-4 - ENDURANCE TEST

2.4.1. The endurance test duration is 400 hours, divided intofour periods of 100 hours each. At the completion ofeach period, the engine shall be submitted to a fullload performance check.

2.4.2. Normal maintenance and adjustment will be permissibleafter each 100 hour test period.

4.3. Engine oil and filters may be changed after each 100hour period.

2.4.4. The engine oil temperature is to be measured in the lu-brication system. The temperature measurement locationshall be specified.

2.4.5. The four 100 hour periods which make up the endurancetest are to be carried out with the fuel defined in2.1.5.

2.4.6. Each 10..b-hour period is to comprise ten 10 hour cycles.Each 10 hour cycle will be carried out in accordancewith the programme (2.5).

The change from one running condition to another shouldbe accomplished within 15 seconds. If not, it must bereported in the test report.

2.4.7) Data will be recorded during the last five minutes ofthe sub-cycles included in the basic 10 hours cycle,with the exception of sub-cycle 5.

2.4.8. No interruptions are permitted during any of the sub-cycles, but the engine may be swi'tched off on comple-tion of any sub-cycle.

-. --- At least 5 times during each 100 hour period, the engi-I,. .ne will be shut down for a minimum of 8 hours.

The engine must be warmed up prior to resumption oftest.

B-14

-32-

-33

1..

SECTION 2-5 PROGRAM OF 10 HOUR CYCLE

Sub- Duration"cycle % Rated Speed % Load in hours

1 IDLE (1) 0

2 100 100 2

3 governed speed (2) 0

4 75 100 1

5 IDLE (1) 11 00 0 100 24 min 6 min

6 60 100

7 IDLE (1) 0.

* 8 governed speed (4) 70 (4)

S9 Max torque speed 1 100 2

10 60 50 (5)

Total 10

NOTES

(1) Deviation from the regulated outlet coolant temperature (96 0 C± 3*C) is permitted

(2) The speed shall be that attained with the engine at fullthrottle and with minimum load (residual brake load)

When the engine is not fitted with a governor, the throttle will

be adjusted to attain 110 % of the rated speed

(3) The moving of the command is shorter than 3 seconds

(4) The speed shall be the steady speed of the engine at fullthrottle and 70 % load.

When the engine is not fitted with a governor the speediwill be103 % of the rated speed

S(5) Part loads (70 and 50 %) shall be taken from the initialperformance test.

- 33 -

.B-15

6 /D2

100

' r

II ,/

I10"" /

3 4

B 1I .V

I I'

( 50 60 70 80 90 10O0 110

k PERCI TAG SPI.ED

II GRAPHICAL PRSE1TIT~AI0 OFV 10 HOUR CYCLE

!t . - 34 -si~. B-16

J -3 -5 -

" SECTION 2-6 - DETAILS OF REQUIRED PRODUCTION AUXILIARY

EQUIPMENT

Inlet system

Inlet manifold ............... YesAir filter.... }Inlet silencer:................ OptionalBlowby gas recirculation 1

intake ..................... }

Exhaust system

Manifold .................................... YesPiping ..................... .

Silencer ................... } Test bench equipmentExhaust pipes ................

Fuel feed pump Yes

Carburettor ......................... Yes (details of adjustmentwill be specified)

Ignition system

Distributor ................................. YesSpark-plugs ................................. Yes

Coils ......... ...................... YesSuppressor .................................. Yes

Fuel injection equipment

Prefilter ................... } Yes or test bench equipmentFilter ...... ...............Pump ..... Yes

High-pressure pipes .......... YesInjector ................................... YesRegulator .................... Yes

-. 4

B-17

'-35

i " 36 -

II

Liquid cooling equipment

Radiator................... NoFan ........................Water pump ................... YesThermostat .................... Yes

Air cooling equipment

Streamlining YesBlower ........................ YesTemperature regulatingdevice ............................. Yes

Electrical equipment ......... o.. Inecessary

Supercharging equipment

Compressor driven directlyor indirectly by the engineand/or exhaust gas ........... YesCharge cooler ................ YesCooling pump or fan .......... Yes

(engine driven)_Device for regulating flowof cooling fluid ............. Yes

Q. B-18

-36-

"" , ' - 37 -

SECTION 2-7 INFORMATION TO BE INCLUDED IN TEST REPORT

A complete report covering all the tests, servicing,maintenance, rectification of faults and the conditionof the engine at the strip examination including themeasurements of the principal wearing arts will be com-piled.

The report will also include the following.

1. A statement of the build standard of the engine,with drawings and a parts list

2. Photographs of the engine from.four different views

3. Photographs of the test installation at least fourdifferent views

4. A list of equipment fitted to the engine

5. Sample test sheets and a summary with a list of-faults and the remedial action taken.Full load performance data will be shown in the formatindi cated.A list gf failures and corrective actions to overcomethem.

6. An engine condition report at end of test with pho-1." tographs of the condition of major parts such as pis-

tons, bearings, valves, camshafts, crankshafts, cylin-der bores together with any other components ofinterest.

7. A trend chart of oil consumption and blow-by duringthe endurance tests.

8. Analysis of new and used lubricating oil, the lat-ter to be taken at approximately 100 hours intervals.

9. Fuel analysis

10. Any other relevant data.

B-19

$ - 37-

c, "OU Type n" IU LCENGINE DATE

IPERFORMANCES A PLEINE CHARGE init REFERENCE

FULL-LOAD PERFORMANCES fln.

C COMBUSTIBLE HUILE FREIN type

FUEL OIL BRAKE

MASSE VOLUMIQUE (15"C) GRADE ____

VOLUME MASS - kg/dinj

S ,n tr/mtin* r.p.m

zSM indan

, =-

o p kwU.c

&p~inm bar

P m m/.pS., A.,toc g wh

Aw

1u. qm kg/h

0

-C

O-p1 in bar

*Z t2 "C

SwwWI_ p,= bar

9 t2 "C

p2-p2" m ba•r

q a kg/a

aB-2

in-l bar

U 3 LJ LJ ba_

B-2

SYMBOL DEFINITIONS

ti : tempdratureof

pi : pressure

air or gas i = 0 ambient= 1 after air filter= 2 after compressor= 2' after charge cooler= 3 turbine inlet= 4 after turbine

fuel i f

oil i =h

water i = e inlet engine= s outlet engine

q : mass flow i = m fuel per hour

= a air per second

qc : volumetric flow injected per cycle and per cylinder

bsfc : brake specific fuel consomption

bmep : brake mean effective pressure

n : rotation speed (engine output shaft)

M : torque idem

p : power idem

-39-

B-21

- - 40- -~

. ¢

C - SCHEMA DE PRINCIPE DE MOTEUR DIESEL ET A ALLUMAGE COMMANDE

- SCHEMATIC DIAGRAM DIESEL AND SPARK IGNITION ENGINE

I

to - po

tI -•

•t2 t2'

ý p2. Moteur

,1 f Engine UI

.......... t3

* t4 -4 P3

B-22

.40-

APPENDIX C

SAMPLE TEST SHEETS

C-I

0 I00.0-0000 0000 000

00 00" 0~000.-000 0000 oo 0, 000

im EWUUOUC LLJ MOO 060U

r .0-m mo * N Cllff * .-s WClOl- .0'w0 Qww0U l- l w.-0

0-O NO,. .0 .C OCl~oC) u l *NN C&Rtl N C '4D

- 040 NNN4 l -C'.CO.-4OCAN0, 0 .- hNoiR) )('b )

I .- ONW .o * ('lO'a.-4f~ * 1* O\O) OXOCON 0.7 r

LJ) N &COO- 00 0 000Q,- Cl-cD.4 G Cob VOClN *f)m Cl _-ýkO ODI II-l~ OD I Ii

"I-IýC~t III iIIIIII N 1(440O ii 04 N-0 1 I!INI(,DI6N'III I i I'I

0I 04 N U)OC 04~ 0-C'O Ca',laNI iIl - 0Cl0-N. O N -N-'.T l~*'' ~o~~CC

(A I Z.- 1111E.IN '.Za I Ill I I

42 E'-- IN 4LU I 'I 'Il~f 'I 'I~)C Nvm'0CNý 01N4x I I-%r U 'I II 1 11 11 '0ONOC4 N0.C-) . qC)0040ID~~) YC4 T c-

A- IZ- i LU nh Il l" I .. 0-O t) C..,4I'4l - . l ~l C 4

ccI I >C U 0 OI Il~ 0- I4 4 I . ' N A N

Uz~ I I If I0 .I4 ItI II 0,0 4 f

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APPENDIX D

PHOTOGRAPHS

D-1

LIST OF PHOTOGRAPHS

PHOTO TITLE PAGE

1. 100 Gallons Per Hour, FRDF D-5Blending System

2. Positive Displacement Pumps of the D-6blending system

3. DF2, TAP Water, and surfactant Barrels D-7

4. DF2, TAP Water, and surfactant Barrels D-8

5. 300 Gallon Storage Tank D-9

6. Side view of DT466 instrumented engine D-10

7. Front View of DT466 instrumented engine D-11

8. Rear view of DT466 instrumented engine D-12

9. Instrumented engine with water cooling D-13tower in test cell

10. Instrumented engine and Dynamometer D-14

11. Instrumented engine and Dynamometer D-15

12. Fuel Injection pump plungers in Housing D-16

13. Fuel injection pump's barrel and D-17delivery valves parts

14. Delivery valve body and delivery valve D-18

gasket

15. Failed delivery valve gasket D-19

16. Nozzle body D-20

17. Nozzle body and cap D-21

18. Glass beads blasted nozzle body and D-22needle valve

19. Test piston, rings and connecting rod D-23

20. Test piston, showing carbon deposit D-24

D-3

21. Glass beads blasted piston D-25

22. Top view of piston D-26

23. Engine Block D-27

24. Intake and exhaust valves in cylinder D-28Head

25. In-line, 6 plungers and barrels fuel D-29injection pump and governor housing

26. Top view of the fuel injection pump D-30plungers and housing

27. Nozzle Body and needle D-31

28. Delivery valve copper gasket D-32

29. Barrel, gasket, delivery valve body, D-33spring, washer and holder

30. Intake and Exhaust valves D-34

31. Intake and Exhaust valves D-35

32. Exhaust Manifold D-36

33. Turbocharger, turbine outlet D-37

D-4

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APPENDIX E

DIMENSIONAL ANALYSIS

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NOZZLE INSPECTION' REPORT PART #6

MAINU0rA C rU Rj R -I At NUOJB(R

PART NUetU@ 0RAWING HUkdjtA R IlyvlilON OAT.ER

Rc¥ySIcN NtUMBL R IX. ORDOCI MIJCn Jloe OtOCiR NUmacr OAtE CC'.IPLrTEO

PRCSCRIOm O DIMENSJON ACTUAL DIMENSION OUT OF TOLEQANCE REMARKS

:'ART

# 6 .0137 'e4PLCS. i .0137 ______ ___ NO CARBON

_2_ .0137 APPEARING ON

3 .0137 THESE 4 holes

4 .0137

NOZZLE PARTS

FOR # 6

PART #ADB- I- 2(-2 -7

LARGE' .575

SMALL .355/.359

HOLE : 1774

8 ,

E i - -SRICHARD MELANSHEK 8 1 •'• •37 __• 11

...... ~r 23I i,,. 82

E- 21

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4 4

E-232 b $/ 2

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DATESHEET OF"

PISTON RING THICKNESS 2ATE S1EET OF1 of IAND WIDTH

ENGINE NO. WORK ORDER(LAB. SOP.) 466T2

RECORDED BY CHECKED BY

MLEANSHEK MELANSHEK

WIDTH

S •. YTHICKNESS

THICKNESS WIDTH

CYL. RING NO. RING NO.

NO.

TOP 2 3 4 5 6 TOP 2 3 4 5 6

MAX. .176 .175 .180 .174 .180 .182 .117 .115 .114 .115 .115 .117

# I MIN.

MAX. .176 .177 .177 .178 .178 .179 .116 .116 .116 .116 .116 .117

# 2 MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

M A X . _ _ _ _ _ w o w

MIN. _____

TAC FORM 4534F22 JUL 60 E-25

-f T•

A .--ý ,•P4 0, Ch"4.,,, ,4

Sf ) F, 2:

- VJJ ,I- , ,P; /

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A I ,,,

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rATE

W~fET OF

ExhAUST AND INTAKE VALVE STEM DIMEN31ONS WIEN.ORODR

(LAB SOP) IRODDr ' CkEC&~LD py -MESSINAMESSINA

A= EXHAUST

GU I DE TOAVEL

LOC. POS IT IION CY.POSIT ION10 O*2 TAPER no LOC. 2 1TAPER

EX. A .3720 3717 ;7 A_____

- OR _ _ -R

IN. a 3720 .3720 INT. A~--

OR - _____

El -_ -- 2 ._1

2 -RO-. --.. - -

3- - - -

AA 37TF20 .37189£INT. I NT. A _ _ _ _ _

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A .3 720 37-2AINT. INT. A

j OREXHi.l37X15 LEN. A

)MT. 371 INT. A

' 6 i-. -R------ _4_

TAC: FOPm1-1 Atim sgw AS!E 27OTO3 R4,A

CINTCR LIleC. uIcIl;4AN

2-21-87 SHE.

INTAKE VAMVE OU!" l C. E Os•: I~t n hst Q,*BA!. SO P.) -yciIOD

-LiS SSINA 1CIiFSSINAA- EXHAUST

B= INTAKE

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LOC. B9THjýL~ 'P~ )TTOM i'PE R I

1 2

a 3748 3738

2 5

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* . 747 ] & *375P __ _ _ _ __ __i

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OR

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L 4-: -- ,,,,_•__

CompomthT PlAwl FUEL INJECTION

NOZZLE INSPECTION REPORT PART # I

ANANUVAC ?UP( S - AL ,iUfUlf

PAR? mumats CRAW IN4 14U&J0fR IVi ON ATEIR

R~vIoN RNNER( IX. ORDER mumaCft Joe ONOCR 14UMSIq R

Pr CSfcP9 D IMECNSION ACTUAL DIMENSION OUT OF TOL.ERANCE REMARKS

PART r#1 0 13 7 (Y 4 PLCS 1) .0312_________

.0312

0312

(4) .0312

PART ADB-150M-208-7

LARGE 7.575

SMALL '.356/ .357 ___

HOLE 2.17 75

NEEDLE PIN .17713 -__

2 1 r

RICHARD MELANSHEK21 2

8 i~ 2 E- 29

'I) I N I I I I I

c'o me-o.f", "A,. F U E L I N J E C T I O N P A R T # 5 "" '

NOZZLE INSPECTION REPGRT PART #56.0ANVPfAC r'UA1l R 5 .1- t Nu, l'AIf0

PAST AUM4|I CR&WING PU64d(f RIA1410M A TUIER

m liic¥ 1 AUlsca 9x. OftOca NUUI[j R JOS OPOR NUMIC• CAT( CO4IPL9190

PRESCRIDED DIMENSION ACTUAL DIMENSION OUT OF TOLEnANCE REMARXS

PA, .0137 4 PLCS ( .0132

2 .0132

A .0132

4 .0132 _ _ _ _ _ _ _ _ _ _ _

PART #ADB-150M-208-7j I"LARGE / 575

S SMALL ) 355/358

HOLE j.1 1775

NEEDLE PIN / .1773

! I•.$1'• |OHPAC.!G NO. No. OF PC $RICHARD MELANSHEK ..

" E,3023? ,:•8 E-30

c rOw*IoftT NAf t FUEL INJECTION ,", U IU.(

NOZZLE INSPECTION1 REPORT PART #3WANVIFAC TU I SPCI.i At NUleIri

PART NUu59l1 ORA*ING r umof A T

lVl~iON DATtfR

a E11INI I UMIOHUN 921x. ORDER tUMItR JOe ORM8C NUMIt" DATE COI.4PLETCO

PRESCRIDED DIMENSION ACTUAL DIMENSION OUT OF TOLERANCE REMARKS

PART# 3

.0137 'A"4/PLCS ni .0132

2_ .0132

n_ .0132

n .0132

NOZZLE PARTS

FOR PART #3 SHIMS ARE MISSING

PART #ADB-150-208-7

LARGE 575

.SMALL .355/.357

ROLE ,,T .1774

S NEEDLE PIN .1773

A

I- _______-___._.: . !,_____

V[IL I 0H PAGE NO. 0. Of PG 5,

* RICHARD MELANSHE.K 1IC 9S11. A,' F".o m 23

6 , :' 2 E - 3 1

C u w ,T'A"' FUEL INJECTION .. ~.

NOZZLE INSPECTION REPORT PART #4

UANUOPAC Tun(0 At Num JI t

PANT "NUMSK3 DRAWINhG 14JMI(A I llmOTL

xKYSIGN flulmolm IX. Opofr NUMBER Jos OROCR fUMIER OAT( Co..wpg?[O

PRESCRIDEO DIMELNSION ACTUAL DIMEN~SION OUT OF T04ERiANCE REMARKS

PARTfl4 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

.0137 ,0" 4 PLCS 1 .0132 'IT

2 .0132 If(Z

3 .0132 Aýr

4 .0132 .-

"..7)T.F PARTS _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

-FOR #_4 _ SHIMS ARE MISSING _____________________

~PART #ADB-150M-208-7 ________________________

LARGE .575

SMALL A 355/ .358 ___________

iHOLE ~ 1774 ___ __ ______

NEEDLE PIN .1773___ ____- _ _______

RTCHARD MELANSHEK21 Li 71

23 E- 32

cO b, o sql. 'm " FUEL INJECTION I f1 tI It P RT

NOZZLE INSPECTION REPORT PART #2Ad APO tif A C T. At It 1.1 At NU'ASr A

PAR? NJuIsts CRAWING PIUMBfN nivr iO, DATLR

REVISION NUmbcx IX. ORDER NUMuSR JOb OR•AO NUMaR ODATE COI.IPL (TEO

PRcSCReIscD OIMCNSION ACTUAL DIMENSION OUT OF TOLERANCE REMARKS

YýRT .037 ' 4/PLCS. ~j' .0132

-2.0132

"_ _•C3_" .0132

(2 .0132

I

NOZZLE PARTS

FOR # 2

SHIMS ARE MISSING

PART #ADB-150M-208-7

LARGE .575

SMALL 4 .356/. 357

HOLE .1774

NEEDLE PIN .1773

S Ih'. kliON PAGE NO. NO.fO" PG 1.

RICHARD MFTNSE 2 1FE3 ~

23 E-323

I i,< 82 E-33

DAMLO/Sro/q Pim B'ecr 2 1 Feb 87 3HE i7o

'o/5 ro r 00. W~INE No. WORK ORDIR466T2 _______

WLORDED &Y CHECKE.D BYIR. MELANSHEK IR. MELANSHE4i

-A STNPN 13606 ~ PiA_ ____ o OD. A 2 PIA -~3 OJIA

A1 1_ 4_ 2342 -4-47 4 2 3

u I___ 1____U4.U

- A

4A

Al A___ 4___ ?___ _ __n____?&7 '__ 4

#___ ____ A__4_?_1 A 4___-_47

Ai_ __ A

LA~~~~ Al__ __ _ _ _ _ _

OR O___ ______

Al _

A A

at M

H E-34

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Commander 12Defense Technical Information CenterBldg. 5, Cameron StationATTN: DDACAlexandria, VA 22314

Manager 2Defense Logistics StudiesInformation ExchangeATTN: AMXMC-DFort Lee, VA 23801-6044

Commander 1U.S. Army Tank-Automotive CommandATTN: AMSTA-CF (Mr. Orlicki)Warren, MI 48397-5000

Commander 2U.S. Army Tank-Automotive CommandATTN: AMSTA-DDLWarren, MI 48397-5000

Commander 12U.S. Army Tank-Automotive CommandATTN: AMSTA-RGEWarren, MI 48397-5000

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