Unclassified SAE J1321 TESTING USING M1083A1 FMTVS INTERIM REPORT TFLRF No. 404 by Adam C. Brandt Edwin A. Frame Robert W. Warden U.S. Army TARDEC Fuels and Lubricants Research Facility Southwest Research Institute ® (SwRI ® ) San Antonio, TX for U.S. Army TARDEC Force Projection Technologies Warren, Michigan Contract No. W56HZV-09-C-0100 (WD 0001) Contract No. W56HZV-09-C-0100 (WD 0002) Approved for public release: distribution unlimited March 2010 ADA
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Unclassified
SAE J1321 TESTING USING M1083A1 FMTVS
INTERIM REPORT TFLRF No. 404
by Adam C. Brandt Edwin A. Frame
Robert W. Warden
U.S. Army TARDEC Fuels and Lubricants Research Facility Southwest Research Institute® (SwRI®)
Approved for public release: distribution unlimited
March 2010
ADA
Unclassified
Disclaimers The findings in this report are not to be construed as an official Department of the Army position unless so designated by other authorized documents. Trade names cited in this report do not constitute an official endorsement or approval of the use of such commercial hardware or software.
DTIC Availability Notice Qualified requestors may obtain copies of this report from the Defense Technical Information Center, Attn: DTIC-OCC, 8725 John J. Kingman Road, Suite 0944, Fort Belvoir, Virginia 22060-6218.
Disposition Instructions Destroy this report when no longer needed. Do not return it to the originator.
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SAE J1321 TESTING USING M1083A1 FMTVS
INTERIM REPORT TFLRF No. 404
by
Adam C. Brandt Edwin A. Frame
Robert W. Warden
U.S. Army TARDEC Fuels and Lubricants Research Facility Southwest Research Institute® (SwRI®)
Approved for public release: distribution unlimited
March 2010 Approved by: Steven D. Marty, Director U.S. Army TARDEC Fuels and Lubricants
Research Facility (SwRI®)
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REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188
Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS.
1. REPORT DATE (DD-MM-YYYY) 31-03-2010
2. REPORT TYPE Interim Report
3. DATES COVERED (From - To) November 2009 – December 2009
4. TITLE AND SUBTITLE
5a. CONTRACT NUMBER W56HZV-09-C-0100
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) Brandt, Adam; Frame, Edwin; Warden, Robert
5d. PROJECT NUMBER SwRI 08.14734.01 & 02
5e. TASK NUMBER WD 0001 & WD0002
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER
U.S. Army TARDEC Fuels and Lubricants Research Facility (SwRI®) Southwest Research Institute® P.O. Drawer 28510 San Antonio, TX 78228-0510
U.S. Army RDECOM U.S. Army TARDEC 11. SPONSOR/MONITOR’S REPORT
Force Projection Technologies NUMBER(S)
Warren, MI 48397-5000 12. DISTRIBUTION / AVAILABILITY STATEMENT UNCLASSIFIED: Dist A
Approved for public release; distribution unlimited 13. SUPPLEMENTARY NOTES
14. ABSTRACT
Three M1083A1 FMTVs were used to test fuel consumption effects of lubricating fluids. An engine oil, transmission fluid, and gear oil were each evaluated to Joint TMC/SAE J1321 Fuel Consumption In-Service Test Proc edure – Type II specifications over a 42 m ile, two speed, test cycle. For the engine and transmission, the baseline OE/HDO-15/40 oil was evaluated against OEA-30 Arctic oil during testing. The GO-80/90 baseline for the a xles was re placed with synthetic SAE 75W- 140 oil provi ded by T ARDEC. Fuel c onsumption improvements were seen of 1.5% in the engine, 0.6% in the transmission, and a decrea se of 0. 84% in the axles. The test results indicate marked fuel consumption improvements when combining fuel efficient lubricants in both the engine and transmission. 15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT
18. NUMBER OF PAGES
19a. NAME OF RESPONSIBLE PERSON
a. REPORT Unclassified
b. ABSTRACT Unclassified
c. THIS PAGE Unclassified
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19b. TELEPHONE NUMBER (include area code)
Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std. Z39.18
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EXECUTIVE SUMMARY
Three M1083A1 FMTVs were used to test fuel consumption effects of lubricating fluids. An
engine oil, transm ission fluid, and gear oil were each evalu ated to Join t TMC/SAE J1321 Fuel
Consumption In-Service Test Pr ocedure – Type II specifications over a 42 m ile, two speed, test
cycle. For the engine and transm ission, the baseline OE/HDO-15/40 oil was evaluated against
OEA-30 Arctic oil during tes ting. The GO-80/90 baseline for the axles was replaced with
Engine: 1.5% improvement in fuel consumption with an accuracy of ±1%
Axle: 0.84% decrease in fuel consumption with an accuracy of ±1%
Transmission: 0.6% improvement in fuel consumption with an accuracy of ±1%
The test results indicate a marked fuel consumption decrease when combining fuel efficient
lubricants in both the engine and transmission.
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FOREWORD/ACKNOWLEDGMENTS
The U.S. Army TARDEC Fuel and Lubrican ts Research Facility (TFLRF) located at Southwest
Research I nstitute (SwRI), San Antonio, Texas, perf ormed this work durin g the per iod
November 2009 through Dece mber 2009 under C ontract No. W 56HZV-09-C-0100. The U.S.
Army Tank-Autom otive RD&E Center, Force Pr ojection Technologies, W arren, Michigan
administered the project.
The authors would like to acknowledge the cont ribution of the TFLRF technical support staff
along with the administrative and report-processing support provided by Dianna Barrera.
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TABLE OF CONTENTS
Section Page EXECUTIVE SUMMARY ............................................................................................................ v FOREWORD/ACKNOWLEDGMENTS ...................................................................................... vi TABLE OF CONTENTS .............................................................................................................. vii LIST OF TABLES ....................................................................................................................... viii LIST OF FIGURES ..................................................................................................................... viii ACRONYMS AND ABBREVIATIONS ...................................................................................... ix 1.0 Background and Objective ..................................................................................................... 1 2.0 Approach ................................................................................................................................ 1 2.1 Vehicle Preparation ................................................................................................................ 1 2.2 Test Facility ........................................................................................................................... 4 2.3 J1321 Testing Procedure ........................................................................................................ 5 3.0 Test Results ............................................................................................................................ 7 3.1 Engine Lubricating Oil .......................................................................................................... 8 3.2 Axle Gear Oil ......................................................................................................................... 9 3.3 Transmission Fluid............................................................................................................... 10 4.0 Summary, Conclusions, and Recomendations ..................................................................... 11 5.0 References ............................................................................................................................ 13 APPENDIX A. Fuel Consumption Data APPENDIX B. Steady State Operating Temperatures APPENDIX C. JP-8 Fuel Certificate of Analysis
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LIST OF TABLES
Table Page Table 1: Major Vehicle Components and Associated Lubricants .................................................. 2 Table 2: Vehicle Serial Number and Testing Weight ..................................................................... 3 Table 3: Lubricant Fill Schedule ..................................................................................................... 4 Table 4: J1321 Testing Steps .......................................................................................................... 5 Table 5: Engine and Transmission Oil Viscosity Data ................................................................... 7 Table 6: Axle Lubricant Viscosity Data ......................................................................................... 7 Table 7: Engine Oil Operating Temperatures and Viscosity .......................................................... 9 Table 8: Axle Oil Operating Temperatures and Viscosities ......................................................... 10 Table 9: Transmission Fluid Operating Temperatures and Viscosity .......................................... 11
LIST OF FIGURES
Figure Page Figure 1: U.S. Army Provided M1083A1 Vehicles ........................................................................ 2 Figure 2: Vehicle on Test Track ..................................................................................................... 4 Figure 3: Fuel Consumption Improvement, MIL-PRF-2104G vs. MIL-PRF-46167D .................. 8 Figure 4: Fuel Consumption Improvement, SAE J2360 – SAE 80W-90 vs. SAE 75W-140 ......... 9 Figure 5: Consumption Improvement, MIL-PRF-2104G vs. MIL-PRF-46167D ........................ 11
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ACRONYMS AND ABBREVIATIONS
% Percent °C Degrees centigrade °F Degrees Fahrenheit ASTM American Society for Testing and Materials Baseline Segment A segment in which the control and test vehicle have identical fluids CAT Caterpilla r cSt CentiStoke CTIS Central Tire Inflation System FMTV Family of Medium Tactical Vehicles GO Gear Oil GVW Gross Vehicle Weight HDO Heavy Duty Oil lbs Pounds mph Miles Per Hour OE Oil Engine OEA Oil Engine Arctic SAE Society of Automotive Engineers T/C Ratio The ratio of fuel consumed in the test vehicle to fuel consumed in the control
vehicle TARDEC Tank Automotive Research, Development and Engineering Center Test Run Combination of one driving cycle of a test vehicle and the baseline vehicle Test/Baseline Segment Three Test Runs which have T/C Ratios within a 2% band TM Technical Manual TMC Technology and Maintenance Council of American Trucking Association
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1.0 BACKGROUND AND OBJECTIVE
The U.S. Ar my desires to increase the fuel e fficiency of its ground vehi cle fleet. One potential
area for fuel consum ption improvement is found in the lubricating fluids located throughout the
driveline. By varying the lubricating fluids used in the vehic les drivelines, a potentia l reduction
in m echanical losses can be ach ieved. These mechanical losses can occur in m any for ms
including frictional, pumping, and churning losses, and are ve ry dependent on the fluid’s
chemical/physical properties and the equipm ent design. A small increase in the overall driveline
efficiency could have a significant impact financially when multiplied over the entire U.S. Army
vehicle fleet. This investigation will look at the fuel consumption effects of engine, transmission,
and axle gear lubricants as used in 5-Ton Cargo M1083A1 variant of the Fam ily of Medium
Tactical Vehicles (FMTV). Fuel consum ption c hanges were determ ined according to the Joint
TMC/SAE J1321 Fuel Consum ption In-Service Test Procedure – Type II(1). Inform ation from
this inv estigation will be used to quantif y th e fuel efficien cy ben efits of three candid ate
lubricants.
2.0 APPROACH
2.1 VEHICLE PREPARATION
Three 5-Ton Cargo M1083A1 FMTV’s were supplie d by the U.S. Army for fuel consum ption
testing. One of the FM TV’s acted as a cont rol vehicle though out te sting running on only
baseline fluids, while the rem aining two vehicles wer e us ed to tes t the candidate oils. New
candidate fluids for the engine, transm ission, and axles were selected for comparison with
baseline lubricants, as speci fied by TM-9-2320-366-10(2), to determ ine potential fuel
consumption improvement. Major driveline components for the M1083A1 are shown in Table 1,
along with baseline fluids, and candidate test fluids as sel ected by TARDEC. In addition, a
picture of the supplied FMTV’s can be seen in Figure 1. The Caterpillar C7 engine was a
turbocharged, air-to-air after cooled engine with a peak power at 2400 rpm. This engine is found
in a large num ber of FMTVs along with the Cougar and Caim an MRAPs and Str yker armored
personnel carrier. The Allison trans mission is an automatic with 7-speed forward and one speed
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in reverse. All three ax les were manufactured by Arvin Meritor and feature single reduction
carriers with am boid gearing and a bevel wheel end reduction. Am boid gearing is sim ilar to
hypoid, but with gear contact above the axle cente rline rather than below it. This allows for
increased ground clearance by raising the driveshaft in the vehicle. Unlike an involute gear, an
amboid gear produces large am ounts of lateral slid ing contact between gear tooth surfaces. This
creates frictional losses in addition to losses from the bulk churning of the fluid.
Table 1: Major Vehicle Components and Associated Lubricants
Front Axle: Arvin Meritor RF-611 7.8:1 Overall Ratio
SAE J2360 – SAE 80W-90 (5) Synthetic SAE 75W-140
Rear Axles: Arvin Meritor RT-611 7.8:1 Overall Ratio
SAE J2360 – SAE 80W-90 Synthetic SAE 75W-140
Figure 1: U.S. Army Provided M1083A1 Vehicles
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Each of the tested veh icles was shipped new from the m anufacturer, BAE Systems located in
Sealy, TX. All vehicles were received with fewer than 150 miles on the odometer. Upon receipt,
all vehicles were inspected for functionality, and instrumented to record tem perature data from
each of the three ax les, engine sump, transmission sump, and ambient air. Secondary fuel tank s
were added and secu red in the cargo section of each truck to be u sed as a weigh tank to
determine vehicle fuel consum ption. Modified fu el lines with quick di sconnect f ittings wer e
implemented to r eadily switch the trucks betw een the prim ary and testing fuel tanks. All fuel
lines were flushed and both the m ain and secondary tanks were filled with JP-8 for the duration
of testing. See Appendix C for fuel analysis. Prior to the vehicles being moved to the tes t site,
alignment was checked and corrected. Tire air pressure was controlled by the Central Tire
Inflation System (CTIS) at Highway setting. As part of standard testing procedure, a double flush
method was used when changing between baseline and candidate fluids to reduce the chance of
cross-contamination between lubricants from one test to the next. After being shipped to the tes t
site, each vehicle was flushed to baseline fluids in preparation of establishing the first baseline
data set for fuel consumption comparison between tes t v ehicles. To atta in us eful resu lts, th e
vehicles must be operated in a m anner consis tent with their typical operating conditions
including: vehicle speed, weight, driving cycle, etc. Ballas t was added to target a gross vehicle
weight of 30,900 lbs and +/- 100 lbs between all three vehicles. T able 2 shows serial num ber
information for the three M1083A 1s, and their test ed vehicle weights that include the driver,
passenger, and full fuel tanks.
Table 2: Vehicle Serial Number and Testing Weight
Vehicle Serial Number Testing GVW (lbs) Control Vehicle 00 B-D701648EHCV 30,968 Test Vehicle 01 B-D701630EHCV 30,977 Test Vehicle 02 B-D701649EHCV 30,984
Candidate fluids were tested independently an d compared to the base line segment immediately
prior to their test segm ent. Fluids in the major com ponents for each segm ent are shown in
Table 3.
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Table 3: Lubricant Fill Schedule
Control Truck Test Truck 1 & Test Truck 2 Engine Transmission Axle Engine Transmission Axle