TO: GEN KEITH, CDR DARCOM, ALEXANDRIA VA
SUBJ: XK1 ENGINE FAILURES
Q. BACKGROUND:
A. The republic of korea indigenous tank
(rokit) program is currently in phase ii which was scheduled to end in june
1984. the end date is now projected for September 1984.
B. During phase II. Two full scale ROKIT
prototypes have been designed, fabricated, and are undergoing testing at
aberdeen proving ground (APG).
C. Two prototypes, designated as PV-1 and PV-2,
were completed in august 1983 and November 1983. Testing began at APG during November
1983 and January 1984 to verify that the components, subsystems, and prototype
vehicles meet the development specification.
D. PV-1 and PV-2 are powered by 1200 hp diesel
engine, Teledyne continental motors (TCM) model AVCR 1790, driving an automatic
transmission, Zahnradfabrik Friedrichshafen (ZF) model LSG 3000, which has
differential steering and braking functions. The AVCR 1790 is a variable
compression ration (VCR) engine.
E. PV-1 is a nonballistic automotive test rig (ATR)
with a non operational turret. PV-1 Is planned to be used for all of the
automotive performance subtests and the endurance and reliability testing.
F. PV-2 is a fire control test rig (FCTR) and
is fully operational version of XK1 tank. it is planned to be used for all of
the fire control subtests.
G. The phase II program is being conducted
under the provisions of a commercial firm-fixed-price contract between the rok
ministry of national defense (MND) and general dynamics land systems division (GDLS).
tee us government's role is one of providing advice and assistance to the ROK program
manager, and as such, has no control over the execution of the contract.
AUTOMOTIVE TEST RESULTS:
A. during automotive performance test from December
1983 to 5 April 1984, pv-1 failed to meet the following required performances:
|
REQUIRED |
MEASURED |
acceleration verification test |
10.5 Second |
14.6 Second |
|
0 to 19.8 MPH |
0 to 19.8 MPH |
60 percent grade slope test |
9.7 MPH |
NOT ABLE |
10 percent grade slope test |
15.2 MPH |
18.6 MPH |
Fuel consumption test |
1.0 miles/gallon |
.6 miles/gallon |
B. A decision
on retest of the corrective actions will be made prior to 1 may 1984.
2. ENGINE
FAILURE HISTORY:
A. PV-1 experienced
loss of power on 13 March 1984. subsequent investigation revealed damage to
several of the VCR pistons and valves the engine was replaced with the spare
and shipped to TCM for failure analysis and repair.
B. The new
engine experienced repeated low oil pressure warning indications subsequent
investigation indicated excessive oil pressure fluctuation. A decision was made
on 27 March 1984 to suspend pv-1 testing pending repair of the engine.
C. ON 5
APRIL 1984, THE PV-2 engine failed while enroute to the firing range. The
investigation revealed damage to one of the VCR pistons and valves. A decision
was made at that time to ship both engines to TCM for rebuild.
D. THE
ENGINE FAILURE |
HISTORY
IS AS |
SHOWN
BELOW: |
|
|
test
vehicle |
operation |
|
milage |
hour |
failure |
|
net/total |
net/total |
date |
|
FIRST
ENGINE FAILURE PV-1 |
949/949 |
75/75 |
13mar84 |
SECOND |
419/1368 |
20/95 |
27mar84 |
THIRD
" |
101/101 |
59/59 |
5apr84 |
4. REPAIR
OF FAILED ENGINES:
A. TCM plans
to rebuild all three engines using fixed pistons instead of the VCR pistons. The
TCM position is that this will not degrade the horsepower. An evaluation of
teat position is underway.
B. The
rebuild time schedule for the first engine is 24 April 1984 second engine, 1 May
1984. Third engine time schedule has not been determined.
5. TEST
SCHEDULE:
During the
mid-point review meeting, (3-13 April 1984), the ROK PM representatives
requested that the first available engine be installed in PV-2.
PV-2 will then
resume fire control testing, and the second engine will be installed in PV-1. at
present, the endurance test has completed about one third of the total mileage
which is 2400 km (1500 miles). A revised testing plan will be coordinated
before 1 May 1984.
6. SHIPPING
SCHEDULE OF PV-1 TO KOREA:
PV-1 is
scheduled to be shipped to Korea on 1 august 1984 for public demonstration on 1
October 1984 (Korean National Army Day). This requirement has priority over the
completion of automotive testing. Engines will be available to support this
requirement. In case the planned automotive test of PV-1 cannot be accomplished
prior to the shipping date, PV-2 will be used to complete the required portions
of the automotive test.
1. TESTING:
A. PV-1 endurance
testing began 14 Jun 84. On 16 Jun 84,
A major
fire occurred in the engine compartment. Damage to engine, left fuel cell,
hydraulic lines, electrical lines and left brake occurred. Possible damage to
left final drive and transmission. All testing on PV-1 Has been suspended and
the tank has been released to GDLS for return to the pioneer engineering
building, Warren, MI. It is expected repairs will take until 1 Aug 64. a
suspected cause of fire is a short in the main power cable assembly. Investigation
is on-going.
B. PV-2 continuing
live fire control checks at APG. The tank successfully finished ballistics
solutions on 20 Jun 84 and has now fired 56 rounds of a 900 round main gun
firing program. No major problems. The power pack was removed on 21 Jun 84 for
check to assure similar shorting conditions did not exist as in PV-1.
2. PROGRAM
ISSUES:
A. Follow-on
MOU hand carried to DA on 15 Jun 84. Staffing in process .
B. Gun
forgings for ROK - DSAA has finalized case.
Case at ROK
embassy for approval.
C. ESP PART
I - Expect ROK to fund 29 Jun 84. In-country start of work (SOW) meting
scheduled for 9-13 July with facilities tour following from 17 - 20 July. PM,
tank systems will have representatives attending.
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