,f; . .

s
HE~AD INSTIWCTIONS
BEFO~E Cmll'I.I;;TING FORM
3. REC,PIc:.NT·S CAl ALOG NUMBER

8. CONTRACT OR GRA

10. PROGRAM ELn.lE~··r, PROJECT, T~.iK

9.PER'F'ORt.:ING ORGANIZATION NAME AND ADDRESS
I AREA 6 VII:.,:!,\tti!2 HUMBERS.
US AR~IT ABERDEEN PROVING GROUNDvtSTEAP-MT-M) DARCQM-R···319-·6
ABERDEEN PROVING GROUND, MARYLAND 21005
II. CONTROLL.''''G OFFICE NAME AND ADDRESS

US AR}N TEST AND EVALUATION CO}MAND (DRSTE-AD-Mj

ABERDEEN PROVING GROUND, MARYLAND 21005
I 14. MONITO~ING AGENCY NAME. & ADDRES$(1f dltlo'f>tIl I,om Conl,014lnQ
-_.-:-t-:-=-~~
Oft/co) ort)

Unclassified
15•• DECLASSIFICATION/OOWNGRADING
SCHEDULE

16. DISTRIBUTION STATEMENT (d /hI. Ropo,t)

~pproved for public release; distribution unlimited.

OT\
EL.ECTE .~ .",

JAN 1 5 '98'
17. OISTf~l)N !>TATEhli::NT (o/lh• • !Jalt.C:! enl",.d In Block 20, II ,iU(o,e.,1 t,Otn Ropo,t)

E ____
1~ SUPPLEMENTARY NOTES

b-----."..------·~-:-:------"':"":-::~~~--;--~:-----------·---__4
1'.
KEY WORDS (Continue on I. v." •• • Ido 1/ n.e......,· ..d Identify by bioelc numb.,)
Air-Cooled Engines Liquid-Cooled Engin~s Steer:tng Effect
Auxiliary Engine Mechanical 1 ransmiss ions Wide-Open Throttle
Cooling Tests Operating Gears
Fluid Tran~missions P~rt Throttl~

Provides guidance;! on how to evaluate the cooling char(l~tcristics of engine,

power train, and auxilial'Y components when suhject~d to full- and part-
throttle vehicle operations, repeated steering maneuvers, and t~xposure to
extreme environments.
'\
FOrut
, JIlM '1J 1473 EDtTlnN Of' , NOVas" OBSOLETI: UNCLASSIFIED
0'-\\'\ ~O
 US ARMY TEST AND EVALUATION COMMAND
TEST OPERATIONS PROCEDURE
DRSTE-RP-702-l0l
*Test Operations Procedure 2-2-607 13 January 1981
AD No.

COOLING SYST~lS (AUTOMOTIVE)

Paragraph 1- SCOPE • • • • , • • • • ~ • • • • . .. 1
2. FACILITIES AND INSTRUMENTATION 1
2.1 Facilities • • • • • • • • • • 1
2~2 Instrumentation • • • • • 2
3. PREPARATIONS FOR TESTS. .. 2
3.1 Vehicle Identification. • ... 2
3.2 Vehicle Preparation • • 3
~.3 Vehicle Instrumentation • . • • • • 3
4. TEST CONTROLS • • • • • • • • 4
5. FERFO~urnCE TESTS . • • • • 4
5.1 Wide-Open-Throttle Cooling Tests (Full Load) •• 4
5.2 Part-Throttle Cooling Tests (Road Load) • 6
5.3 Auxiliary Engine Tests • • . • • • • • • • • 7
5.4 Temperature Rise from Steering (Track~d
Vehicles) • • • • • • • • • •
5.5 Hot-Dry Temperature Tests • • •
6. DATA REDUCTION AND PRESENTATION • • • • • •

1. SCOPE. The procedures in this TOP describe how to evaluate the

cooling characteristics of engine, power-train, and auxili3ry components
when subjected to full- and part-throttle vehicle operations, repeated
steering maneuvers, and exposure to extreme environments. the necessity
for engine and power-train ccoling arises from inherent mechanical end
thermal limitations of vehicle components and their lubricants, heat
buildup from sources such as ambient temperature .~nd solar radiatiun,
and increased operational demands resulting from ()verlo~cis or inCrE!asing
loads. To prevent deleterious effects to power-pr,)ducing and power-
transmitting components, care must be exercised by ~he user to see that
operating temperatures are maintained within specifi~c limits under all
conditions.

f
2. FACILITIES AND INSTRUMENTATION. A';;~~~~~on F~;­
-l~i'I:~' C,;UH ----~
2.1 Facilities. n:r: T~~ ~-
"...~:.1;Jn"1~'·1"1('t\rJ rJ
Mobile field dynamoMeter. I Ji~~, U f'i c; 1 C' ' - - - - - - - 4
\--_._------
!
DO o;l - '~.<AI-
•. '1/ • .---(

*This TOP su?ersedcs MTP 2-2-607, 7 November 1980. R:r --------------1

Di~,tri'_"~tionl

Approved for public release; distribution unlimited. ~~~il:~il!ty Cod~s

-----'i:v~til and!or--
Dist i Spcc'al
TOP 2-2-607 13 January 1981

Cross-country test courses. as required.

Paved test courses which provide for continued operatio:1 at sus-

tained speeds.

2.2 Instrumentation.

ITEM MAXI~IDM ERROR OF MEASUREMENT*

Temperature transducers and floC (±2°F)

recording systems

Pressure-measuring devi~es ±l% of full scale range

Tachometers (engine and wheel ±0.5% of full scale range

or sprocket speeds)

Vehicle spe~d-measuring device ±0.2 km/hr (±0.2 mph)

Force-measuring device ±0.5% of full scale range

Air flow indicators ±10% of reading

Meteorological equipment Ambient air temperature to ±l C (±2°F)

J

Relative humidity to ±3%

. Atmospheric pressure to ±0.3 MB
(±O.Ol ill. llg)
Wind speed to ±1.5 knots
Wind direction to ±3 degrees
Solar r~diation to ±4% of full scale

3. PREPARATIONS FOR TESTS.

3.1. Vehicle Identification. Record the following:

a. Vehicle model, serial number, and manufa~turer.

b. Vehicle engine model, serial number, manufacturer. and maxi-

mum operating temperature (engine oil and coolant OT cylinder head).

c. Vehicle tLansmission model, serial number, manufacturer, and

maximum operating temperature.

d. Maximum operating temperatures of other gearboxes.

e. Gear ratios of all ~earboxes.

*Values may be aS3umed to represent ±2 standard deviations except where

indicated; thus the stated tolerances should not be exceeded in more
than 1 measurement out of 20.
2
13 Januat'y 1981 TOP 2-2-601

f. Sprocket rolling distance.

g. Vehicle cooling requirements per vehicle specifications,

materiel need, etc.

3.2 Vehicle Preparation.

j.2.l Method.

a. Insure that the vehicle has been subject to the applicable

portions of TOP 2-2-505 prior to performing tests.

b. Perform maintenance and servicing to insure that the vehicle

is in condition for optimum performance. Give particular attention to:

(1) Cooling syste~.

(2) Igni tion f:im:lng.

(3) Fan belt tension.

(4) Proper lubricants and lubricant levels.

(5) Proper operation of pressure caps, heat riser valves,

and any other components that affect engine and power-train component
temperatur.e directly.

c. Block open all thennostats to permit maximum coolant or oil

flow, and alter thermostatically contro. led fans to obtain positive
drive, as required.

d. Insure'that the vehicle contains the proper fuel per enginE~

specifications, and the appropriate liquid coolant when applicable.
Specific guidance in TMs; if nene, 50% water/50% ethylene-glycol mix-
ture, except when arctic antifreeze is required.

e. Load noncombat test vehicles to gross weight and cOll'.hat ve-

hicles to combat weight.

3.2.2 Data Require~. Record the fbCt that actions epecified iu Para-
graph 3.2.1 above have been completeci.

3.3 Vehicle Instrumentation.

3.3.1 Method. Instrumentation includes the following:

a. Thermocouples to measure critical engine, power-train and

auxiliary component tempHr;tures as required for each specific vehicle
to adequately determine and evaluate c,.....,!ing characteristics.

3
TOP 2-2-607 13 January 1981

b. Transducers, pressure g~bes, and vacuum gage3 as required.

c. Air flow indicators aF required.

d. Engine tachometer.

e. Vehicle speed-measuring device.

f. Sprocket or wheel speed tachometers.

4. TEST CONTROLS. These t~~ts are limited to engines and power trains
contained in vehicles. TeBts will not be conducted in snow, rain, high
wind, or when vehicle power is known to be below normal for reasons
other than atmospheric conditions. Since wind effects may vary appreci-
ably wIth vehicle design because of influences on air flow and recircula-
tion, the limits are based on temperature effect rather than pressure.
Tests, therefore, will not be conducted in wind causing a varia~ion
greater than 6°C (lO°F) in engine oil, 3°e (S°F) in engine coolant, or
30°C (S4°F) in average cylinder-head temperatures when the direction of
vehicle travel is reversed. Cooling tests are not conducted at ambient
temperatures below 21°C (70°F), due to probable extrapolation error.
(Extrapolation of results is based on a one-degree rise in component
temperature per one-degree rise in ambient temperature.)

5. PERFORHANCE TESTS.

5.1 Wide-Open-Throttle Cooling Tests (Full Load).

a. Meth-:;u.

(1) Use a ~obile field dynamometer and its related equipment

-to supply a full-lo~d condition to the vehicle under test.

(2) Operate the vehicle at full throttle over a straight,

approximateJ.y level, paved road.

b. Dat~'_ Required. Record applicable data in Paragraph 5.1. 5.

5. L 1 Vehich~s with Liquid-Cooled or Air-Cooled Engines and Mechanical

Transmissions (!ransmission in Lowest Operating Gear).

a. Meth:>d.

(1) Place the tr'lnsmission in the lowest operating gear in

~lich the vehicle has sufficient traction.

(2) Operate the vehicle at an engine speed which provides

maximum engine torque output until all component temperatures stabilize
at or below the critical lim:lts specified for components. If a critical
temperature is experienced, :lncre.ase vehicle spf~ed (decrease drawbar
loading).
4
13 January 1981 TOP 2-2-607

(3) Repeat above test at maximum engine power or at maximum

enziI:e speed (governor interference must be eliminated).

(4) Additional tests may be conducted at speeds between

those obtained in (2) and (3) above to predict cooling characteristics
in higher ambient temperatures up to 49°C (l200F), or as specified in
the equipment specification.

(5) Data obtained after temperature stabilization must be de-

rived from equal operational time in both directions to minimize wind
effects.

b. Data Required. Record the applicable data requirements of

Paragraph 5.1. 5.

5.1.2 Vehicles with Liq~id-Cooled or Air-Cooled Engines and Mechanical

Transmissions (Transmission in Highest Operating Gear).

a. Method.

(1) Place the transmission in the highest gear.

(2) Operate the vehicle at the maximum vehic. eugine speed

limited by power, without the dynamometer, until the power-train COm-
ponent temperatures stabilize or exceed specified limits.

(3) Obtain equal amount of data with the vehicle traveling

in each direction.

b. Data Required. Record the applicable data requirements of

Paragraph 5.1.5, vehicle speed and engine speed.

5.1.3 Vehicles with Liquid-Cooled or Air-Cooled Enaines and Fluid Trans-

missions (Transmission in Lowest Operating Range).

a. Method.

(1) Place the transmission in the lowest operating range in

wMch the vehicle has sufficient traction.

(2) Operate the vehicle at maximum torque or lowest converter

speed ratio that will permit COTlT'onent temperatures to stabilize within
critical limits in the preva).li.~g ambient temperatur~.

(3) Determine the converter speed ratio where components

should cool in specified maximum, ambient temperature (hy extrapolation
of temperatures).

(4) Repeat the test at maximum engine powe~.

5
TOP 2-2-607 13 January 1981

(5) Repeat the test at a minimum vf two other speeds between

maximum torque (or lo'·;<..st converter speed ratio) and maximum power to
establish component cooling cha~acteristics.

(6) Obtain equal amount of data in ea~h direction of travel.

b. Data Required. Record the dat~ specified in Paragraph 5.1.5.

5.1.4 Vehicles with Liquid-Cooled or Air-Cooled Engines and Fluid Trans-

missions (Transmission in Highest Operating Range).

a. Method.

(1) Place the transmission in its highest range.

(2) Operate the vehicle at maximum vehicle/engine speed

limited by p0.Jer, without the dynamometer, until the power-train com-
ponent temperatures stabilize.

(3) Obtain equal amount of data in each direction of travel.

b. Data Required. Record the applicable data requirements of

Paragraph 5.1.5, vehicle speed and engine speed.

5.1.5 Data Required. Record the following during all full-throttle

cooling tests:

a. Component temperatures, ~ressures, and cooling air flow rates

dire~tly pertinent to engine and power-train cooling characteristics.

b. Drawbar pull, ~ngine speed and vehicle speed.

c. Meteorological data (ambient temperature, wind speed, wind

ditection, and solar radi~tion).

5.2 Part-Throttle Cooling Tests (Road Loadt.

5.2.1 Meth"d.
a. Operate the test vehicle over the test course at one or more
sustained operating speeds until the power-train component temperatures
stabilize.

b. Obtain equal amount of data in each direction of travel.

5.2.2 Data Requireci. Record the following for all test vehicles:
•.
a. Component temperatHres, .lressures, and cooling air flow rates
directly pertinent to engine and power-train cooling characteristics.

6
13 January 1981 TOP 2-2-607

b. Average vehicle and engine speeds.

c. Meteorological data.

5.3 Auxiliary Engine Tests. Ii

5.3.1 Method.

a. Determine the cooling characteristics of auxiliary engines.

b. Attach a load bank to the auxiliary engine, and subject it

to tests with the main engine operating.

c. Operate the vehicle over a paved highway at maximum engine

torque output until a critical component temperature exceeas e~tablished
1imjtations. Record data in Paragraph 5.3.2a(5) through 5.3.2a(13).

d. Operate the auxiliary engine at 75% of its rated load until

its critical component temperature stabilizes and record data as pre-
scribed in 5.3.2b.

e. Operate the auxiliary engine at 90% of its rated load until

its critical component temperature stabilizes and record data as pre-
scribed in 5.3.2b.

f. Operate the euxiliary engine at 100% of its load until its

cri.tica1 component temperature stabilizes and record data as prescribed
in 5.3.2b.

5.3.2 Data Required.

a. Record the following after step 5.3.lc:

(1) Location of the auxiliary engine.

(2) Auxiliary engine model, serial number, and manufacturer.

(3) Auxiliary engine maximum allowable te"lllJerature.

(4) Auxiliary engine rated load.

(5) Vehicle transmission position.

(6) Metecrological data.

(7) Vehicle directiou,

•.
!/ T~lissubtest is not essentinl or relevant to every test program, but
may be condu(:ted at the discretion of the evaluator.

7
TOP 2-2-607 13 January 1981

(8) Air induction through the vehicle engine compartment.

(9) Air induction through the turret, i f applicable.

(10) Vehicle engine oil pressure.

(11) Engine speed.

(12) Vehicle speed.

(13) Air temperature around the ~uxiliary engine prior to

operating the auxiliary engine.

b. Record the following:

(1) Auxiliary engine critical component stabilized tempera-

tute.

(2) Vehicle critical component temperatures.

5.4 Temperature Rise from Steerina-(Tracked Vehicles). 1/

5.4.1 Method. Determine the effect of transmission-contro~Leust~ering
systems (track laying), when applic.able, as follows:

a. Prepare the vehicle so that i ~strumented and loaded as

stated in Paragraph 5.2.

b. Operate the test vehicle over a deHned test course, requiring

frequent steering maneuvers, at ulaximum safe operatin~ speed.

c. Operate the veh:f.cle a sufficient period :1£ time to determine

whether critical component temperatures exceed limitations.

5.4.2 Data Required. Record the followi~g:

a. Meteorological data.

b. Component temperatures, pressures, and air flow rates pertinent

to evaluation of differential steering effects.

c. Average v~hicle speed.

d. Average engine speed.

5.5 Hot-Dry Temperature Tests. test the vehicle-engine combination in

accordance with TOP/MTP 2-4-001 and Paragraphs 5.1 and 5.2 of this TOP
as applicable at an ambient air temperature as close to +49°C (+120°F),
or as otherwise specified.

8
13 January 1981 TOP 2-2-607
6. DATA REDUCTION AND PRESENTATION.

6.1 Full·-Throttle and Part-Throttle Cooling Tests. Data shall be pre-

sented in tabular and/or graphic form (tndcal graphs al:e shown in Fig-
ures 1 and 2). Average stabilized temperat~res arc preuented for each
operational condition in the prevailing ambient t and these temperatures
are also extrapolated to the specified maximum ambient temperature.

The apparent effects of auxiliary engine, di.fferential steering,

etc., upon the vehicle engine cooling systems shall be su~~arized.

6.2 Auxiliary Engine Date. Data shall be summarized to indicate the

effect of the mai~ engine and heated compartments u~Jn the auxiliary
engine cooling ability under various loads.

9
 13 JanuaL'Y 1981 TOP 2-2-6O'l
Vehicle:
Engine Model:
Transmission Model:
Gear Range:
Ambient Temperature:
Veh-r.~.J e Weight:

Date(s, of Test:

20

I
~Iu 16
0
J

~
U)
U)

~
u
<
u
~ 12

-/
0

~
~
~ 8
~
f-l

80
"
~ ~
~
",

40 0 4 8 12 16 20

SPEED - KILOMETERS PER HOUR

Figure 1. Enaine 011 Temperature Characteristics During Full-Throttl,~
Operation.

10
TOP 2-2-607 13 Januar
Vehicle:
Engine Model:
Transmission Model:
Gear Range:
Ambient Temperat~re:
Vehicle Weight:
Date(s) of Test:

150

120

ntermediat

u 90
0

~ Rear

~
~
60
~
f-4

JO
.. 0

o
o 40 80 120 160

TIME - MINUTES
•
Figure 2. Differential Oil Temperature Ri~e Characteriqticf
Part-Throttle Op~ration.

11
TOP 2-2-607 13 Janunry 1981

Recommended changes to this publication should be forwarded to

Conmander, US Army Test and Evaluation Comlnand, ATTN: DRSTE-AD-M,
Aberdeen Proving Ground, MD 21005. Technical information may be
obtained from the preparing activity: Commander, US Army Aberdeen
Proving Ground, ATTN: STEAP-MT-M, Aberdeen Proving Ground, ~ID 21005.
Adlitional c0pies are avuilab1e from the Defense Technical Informp-
tion Cente~, Cameron Stati~n, Alexandria, VA 22314. This do~ument
is id~ntified by the accession number (~) No.) printed on the first
page.

12