The new build engine has made it’s madden run. It took some effort to bleed the air out of the fuel system as we normally run a hi volume 12Bar or 174PSI fuel lift pump so I came to live more or less as a WO2 airplane engine.

I must say it was a real relief to see the engine running 2000Rpm with no problem as we had to do some unplanned modifications to get valve piston clearance as the camshaft was not made according to pacification so we now got more aggressive inlet valve lift on the engine.
For now it’s hard to say how the engine will run as there is still a load of air in the injectors that can only go out true the nozzle as these injectors have no fuel return or bleed valve.

Next step is getting the speed sensor in from BorgWarner and install this in the Holset HX60 to get data and map this out in the compressor flowmap so we know where we are and what we are going to need for turbochargers.
I want to start testing with the turbo set-up we used last year as this will be the fasted to fit to the test set-up and runs without any air/oil pluming problems.
Parallel to this we going to build the new exhaust manifolds with a compensation tube between the to manifolds and install a wastegate valve in the middle of the tube.

 

Last week we start getting a lot of parts from the truck so we can build these on to the new engine and make it possible to run and collect all the data.

Martein made this test set-up by getting all the engine control parts located in different parts of the truck on a pole.
From bottom upwards are the power distribution and main relay and o2 sensors control. Above that is the 24V to 12V converter as most European trucks run a 24V system and the engine controller (the black box with the bleu plug) and o2 sensors run on 12V.
On top of the pole is an alloy plate with two lamps and an ignition key. One lamp is to indicate that the electric fuelpump is on and the other lamp is status indication for the remote system we installed to run the fuelpump. For safely we also made an option to stop the engine by the same remote so as long as you have the remote with you, you will be able to shut the whole system down in an emergency.



Demo movie of what truck pulling in Holland looks like.


Martien almost get the whole truck airborne on the end of this run.

 

Yesterday we had a bit more fun getting the engine up to max RPM te first time and pre commissioning the race UEU system. This thing sounds more like a V8 hotrod engine.

https://www.youtube.com/watch?v=GxOS...gIA&playnext=1

https://www.youtube.com/watch?v=sHH5...1&feature=plcp

 

Small update. We have radio silence on this project but I think the pictures will explain some.

 

We did have the engine up to about1100 to 1200Hp and 3Bar or 43PSI boost and then we blow up the flexible exhaust tubing between the turbo and the muffler system twice so tomorrow we going to modify it and hope the mufflers will not create a lot of back pressure.
Good thing is we can connect some more pressure sensors so I can log some more data to see what going on.

 

I finally got my turbo speed sensor installed and able to plot out the speed and boost pressure in the compressor flowmap.
Still struggling to get cylinder 5 to 8 to burn a lot more fuel, hope changing the fuel feed rail will solve it.

 

We just finished the first part of our testing on the dyno going over 1500Kw and 5KNm.

 

Let the game begin.

 

Yesterday we completed the last bit of wiring on the engine and I manage to drive the truck outside to setup the RPM governor and ALS.

I set-up the ALS to 1Bar or 15PSI boost and the governor max RPM to 2900 and I get what I want spot on, so yes I’m happy with the ECU setting so far. Also our truck driver was very happy and find the engine extreme aggressive on accelerator response.

What is still left is a load of work on safety stuff shielding of turbochargers and air intakes and redo some of the controls on the air shutoff valves.

 

Sweet victory on the first real test for the engine. Last Sunday we had our first demo event in Loosbroek on a wet stand track as we had a lot of rain in the day upfront to the event.

First pull went OK but we could not get the power on the track so good for a shakedown to have a look if bits and pieces came of.

Second pull we changed the balance of the truck and on the end of the pull we finally get some power on the tack so we could test if the wastegate was doing its work. Not bad 15 second pull on this bad stand track.


The pull off. In this run we set the boost controller to 4 Bar or 58 PSI and as expected the wastegate stay closed and turbo speed went up to the max so on the end of the pull the torque reduction kicked in hard as I set it up very save to prevent turbo damage as we still need to fine tune a lot of things and settings. We did get a full pull and won the demo event by more than 17 meter so yes I’m very happy and al the hard work paid of so far.

We changed the way the ALS works to spool up the turbochargers to 1.2Bar or 17 PSI, strange sound on the begin of the pull.

I’m also very happy with all the extra data we generate as this gives a better picture on loads of things like we know now that with this engine set-up we go from 3 Bar exhaust pressure to 4 Bar exhaust pressure when we change the boost pressure from 3.5 Bar to 4 Bar. This make it’s more than clear that the HX60 is on the max of what it can handle.