Attachment 0002 3 kW PURCH_DESCRIPTION - PD 6115-0076D.pdf

PD 6115-0076D

20 December 2019

PURCHASE DESCRIPTION

GENERATOR SETS, DIESEL FUELED, SKID MOUNTED,

LIGHTWEIGHT, TACTICAL, QUIET, 3 kW

Prepared by:

PROJECT MANAGER-EXPEDITIONARY ENERGY AND SUSTAINMENT SYSTEMS

5850 DELAFIELD ROAD, BLDG 324

FORT BELVOIR, VA 22060-5809

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

Beneficial comments (recommendations, additions, and deletions) and any pertinent data which may be of use in improving this document should be addressed to: PROJECT MANAGER-EXPEDITIONARY ENERGY AND SUSTAINMENT

SYSTEMS, ATTN: SFAE-CSS-E2, 5850 DELAFIELD ROAD, BLDG 324, FORT BELVOIR,

VA 22060-5809, by letter or emailed to usarmy.belvoir.peo-cs-css.mbx.pdm-small-power-source-ops@mail.mil.

rosetta.wisdomrussel Typewritten Text

ATTACHMENT 0002

1. SCOPE

1.1 Scope. This Purchase Description (PD) defines the detail

requirements for 3.0 kilowatt (kW) tactical quiet generator sets (hereinafter referred to as "set" or "sets") model MEP-831 (60 Hertz (Hz)) alternating current (ac), skid-mounted, and diesel fueled.

1.2 Classification. The sets shall be type I (tactical), 3.0 kilowatt in size, and of the following mode in accordance with MIL-STD-1332:

MODE: III - 60 Hz, Model MEP-831.

1.3 Set rating. The sets shall be rated 0.8 power factor, lagging, and shall be re-connectable for the following voltage ratings:

a. 1 Phase, 2 wire, 120 volts.

b. 1 Phase, 3 wire, 120/240 volts.

2. APPLICABLE DOCUMENTS

2.1 Government documents.

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, handbooks, and commercial item descriptions form a part of this PD to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

COMMERCIAL ITEM DESCRIPTIONS

MILITARY SPECIFICATIONS

A-A-50271 -Plate, Identification.

A-A-55804 -Rods, Ground (with Attachments).

MIL-DTL-46162 -Fuel, Diesel, Referee Grade.

MIL-DTL-53072 -Chemical Agent Resistant Coating

(CARC) System, Application Procedures and Quality Control Inspection.

MIL-DTL-83133 -Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-34), NATO F-35, and JP-8+100 NATO F-37).

MIL-L-85762 -Lighting, Aircraft, Interior, AN/AVS-6 Aviator's Night Vision Imaging System (ANVIS) Compatible.

MIL-PRF-2104 -Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service.

MIL-PRF-21260 -Lubricating Oil, Internal Combustion Engine, Preservative and Break-in.

MIL-PRF-46167

-Lubricating Oil, Internal Combustion

Engine, Arctic.

MIL-PRF-7808 -Lubricating Oil, Aircraft Turbine Engine, Synthetic Base.

MILITARY HANDBOOKS

MILITARY STANDARDS

NATO STANDARDS

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the ASSIST Database located at http://quicksearch.dla.mil/)

2.1.2 Other government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this PD to the extent specified herein. Unless otherwise specified, the issues shall be those in effect on the date of the solicitation or contract.

OTHER

(The Army Test, Measurement and Diagnostic Equipment (TMDE) Preferred Items List can be found at https://pd-tmde.us.army.mil/TMDE_Home_TEMOD.html.)

MIL-HDBK-1791 -Designing for Internal Aerial Delivery in Fixed Wing Aircraft.

MIL-HDBK-454 -Standard General Guidelines for Electronic Equipment.

MIL-HDBK-784 -Guidelines - Designs to Minimize Contamination and to Facilitate Decontamination of Military Vehicles and Other Equipment: Interiors and Exteriors.

MIL-STD-129 -Military Marking for Shipment and Storage.

MIL-STD-130 -Identification Marking of US Military Property.

MIL-STD-1472E -Human Engineering.

MIL-STD-1474C -Noise Limits for Military Materiel

(Metric).

MIL-STD-209J -Interface Standard for Lifting and

Tiedown Provisions.

MIL-STD-2169A -High-Altitude Electromagnetic Pulse

(HEMP) Environment (Secret).

MIL-STD-461C -Electromagnetic Emission and

Susceptibility Requirements for the Control of Electromagnetic Interference.

MIL-STD-462 -Measurement of Electromagnetic Interference Characteristics.

MIL-STD-705 -Mobile Electric Power Systems.

MIL-STD-810D -Environmental Test Methods and

Engineering Guidelines.

MIL-STD-882 -System Safety.

AFLP-3747 -Guide Specifications (Minimum Quality Standards) for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, F-40, and F-44).

(No Document No.) -The Army Test, Measurement and Diagnostic Equipment (TMDE) Preferred Items List.

ARMY REGULATIONS

DRAWINGS

US Army Communications Electronics Command (CECOM), Fort Monmouth, NJ.

Drawing No.

TECHNICAL MANUAL

US ARMY SUPPLY CATALOG

(Copies of specifications, standards, handbooks, drawings, publications, and other Government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Officer).

2.2 Non-government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

(Application for copies should be addressed to the National Electrical Manufacturers Association, 2101 L Street, NW, Washington DC, 20037.)

AR 700-101 –Joint Operating Procedures Management and Standardization of Mobile Electric Power Generating Sources.

19207 11674728 -Vehicle Receptacle Assembly.

30554 69-668 -Line, Fuel, Auxiliary.

30554 69-692 -6 -Terminal load.

30554 98-19591 -Rail Tie-Down Diagram and Procedure, Power Plant Assembly.

30554 98-19592 -Wiring Harness, Control Box, 60 Hz.

30554 98-19633 -Wiring Harness, Engine 60 Hz.

30554 98-831 -Generator Set, 60 Hz.

*TM 9-6115-639-

13&P

-Operator and Field Maintenance Manual including Repair Parts and Special Tools List for 3 kW Tactical Quiet Generator Set MEP-831A (NSN 6115-01-

285-3012) (EIC VG6) MEP-832A (NSN

6115-01-287-2431) (EIC VN7).

PN 5180-95-B48 -Department of the Army, Tool Supply Catalog, Tool Kit, General Mechanics.

SC 4910-01-95-A81 -Department of the Army, Shop Equipment, Standard Automotive Tool Set (SATS).

SC 4910-95-CL-A62 -Department of the Army, Tool Supply Catalog, Shop Equipment, Automotive Maintenance and Repair.

MG1 -Motors and Generators.

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) Handbook of Standards

(Application for copies should be addressed to the Society of Automotive Engineers, Department 105, 400 Commonwealth Drive, Warrendale, PA 15086 or can be found online at https://www.sae.org.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

(Applications for copies should be addressed to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036.)

UNDERWRITERS LABORATORIES INC

(Applications for copies should be addressed to Underwriter’s Laboratories Inc., 1285 Walt Whitman Road, Melville L.I., NY 11747.)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

(Application for copies should be addressed to the National Fire Protection Association, Battery March Park, Quincy, MA, 02269-9904.)

ASSOCIATION OF AMERICAN RAILROADS

(Application for copies should be addressed to Association of American Railroads, 50 F Street, NW, Washington, D.C. 20001.)

THE INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS, INC

(Applications for copies should be addressed to IEEE Customer Service Center, 445 Hoes Lane, P.O. Box 1331, Piscataway, NJ 08855-1331.)

SAE AS22759/16A -Wire, Electric, Fluoropolymer- Insulated, Extruded ETFE, Medium Weight, Tin-Coated Copper Conductor, 600-Volt, 150 oC.

SAE J1127 -Low Voltage Battery Cable.

SAE J514 -Hydraulic Tube fittings.

ANSI ASQ Z1.4 -Sampling Procedures and Tables for Inspection by Attributes.

ANSI C39.1 -Requirements for Electrical Analog Indicating Instruments.

UL-62 -UL Standard for Safety Flexible Cords and Cables.

UL-94 -Tests for Flammability of Plastic Materials for Parts in Devices and Appliances.

NFPA 70-1993 -NATIONAL ELECTRIC CODE.

Section 6 -General Rules Governing the loading of DOD Material on Open Top Car.

IEEE 315 -Graphic Symbols for Electrical and Electronics Diagrams.

AMERICAN SOCIETY FOR TESTING MATERIALS (ASTM INTERNATIONAL)

(Applications for copies should be addressed to ASTM Headquarters, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959 or service@astm.org.)

2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Description. The individual set requirements shall be as specified herein and in accordance with (IAW) the Top Assembly (TA) and the lower level drawings for:

Model Top Assembly Drawing Title MEP-831 30554-98-831 Generator Set, 60 Hz.

In the event of any conflict between the requirements of this specification, the TA, and the lower level drawings, the former shall govern.

3.1.1 Drawings. The drawings forming a part of this specification are end product drawings. No deviation from the prescribed drawing requirements is permissible without prior approval of the contracting officer. Where tolerances could cumulatively result in incorrect fits, the contractor shall provide tolerances within those prescribed on the drawings to ensure correct fit, assembly, and operation of the set. Any data (such as shop drawings, layouts, flow sheets, and processing procedures) prepared by the contractor or obtained from a vendor to support fabrication and manufacture of the production item shall be made available, upon request, for inspection by the contracting officer or the designated representative.

3.1.2 Configuration management. The generator sets controlled by this specification are under the configuration management authority of the DoD Project Manager for Expeditionary Energy and Sustainment Systems. All engineering change proposals (ECPs)and request for variance (RFV) must be processed in accordance with AR 700-101, AFI 63-110(I), NAVFACINST 4120.12, MCO 11310.8C, DLAI 4120.16 Joint Operating Procedures Management and Standardization of Mobile Electric Power Generating Sources.

3.2 Sets.

3.2.1 Not used.

3.2.2 Production qualification test (PQT) sets. When specified (see 6.2), ten (10) 60 Hz production qualification sets (see 6.5) shall be provided for inspection and testing to prove prior to starting production that the contractor’s production line is capable of producing sets that comply with the requirements of this PD. Inspection and testing shall be as specified in section 4; and unless otherwise specified (see 6.2), all inspections and tests shall be performed by the contractor subject to surveillance and approval by the Government.

ASTM-D1655

-Standard Specification for Aviation Turbine Fuels.

ASTM-D975 -Oils, Diesel Fuel.

3.3 Reliability. The minimum acceptable mean-time-between-failure (MTBF) for the sets shall be 500 hours under the conditions specified in 4.8.2.18.

3.4 Audio noise. Audio noise sound-pressure levels (SPL) emanating from the set shall not exceed 72 dB(A) at 7 meters from the perimeter of the set at

1.2 meters above the ground. In addition, audio noise SPL emanating from the set shall not exceed 85 dB(A) at the operator's station, defined to be a 0.7 meter hemisphere radiating outward from any point on the plane defined by the front of the control panel. These requirements shall apply under all operating conditions specified herein with the set operating at all loads from no load up to and including rated load (see 6.3.14). These requirements shall apply with the set on the ground.

3.5 High-altitude electromagnetic pulse (HAEMP). The set shall withstand the HAEMP nuclear environment specified in MIL-STD-2169 High-Altitude Electromagnetic Pulse (HAEMP) Environment in both operating and non-operating conditions. The set shall meet operational requirements specified herein within 5 minutes (recover) after being subjected to the specified HAEMP nuclear environment. The recovery may include manual or automatic correction of HAEMP induced changes in the set, to include restart, but not the replacement of piece parts or components. The cables to the load shall be 100 feet in length and sets and other equipment shall be configured for worst-case system response during the exposure.

3.6 Nuclear, biological, and chemical contamination survivability (NBCCS). The set shall have a Chemical Agent Resistant Coating (CARC) painted as specified in 3.39. The set shall be capable of being operated and serviced (see 3.17) by personnel wearing Mission Oriented Protective Posture IV (MOPP IV) chemical, biological, and radiological clothing (see 6.3.11) without special tools or support equipment. The set shall not be damaged (see 6.3.2) and shall meet operational requirements specified herein within 60 minutes after being decontaminated according to the procedure specified in Appendix B.

Lenses or covers, gaskets, seals, marking, control knobs, and other devices on the control panel or display functions shall not be damaged by the NBC decontamination procedure. Any changes to the set shall be made in such a way as to minimize the collection and retention of agents and decontaminants.

Design guidance is available from MIL-HDBK-784.

3.7 Electrical performance. Set electrical performance shall be as specified herein. Set rating shall be 3.0 kW at 1000 feet altitude and 107 oF.

Components of the set shall not be damaged (see 6.3.2) when the set is operated continuously at all possible frequency and voltage adjustments. The set shall provide the applicable load rating (see 3.8.2) at the output terminals under all operating conditions specified herein.

3.8 Starting, operating, and stopping.

3.8.1 Starting. The set shall start (see 6.3.18) within 5 minutes with the battery and without the battery under any combination of the following conditions:

a. At ambient temperatures from –25 oF to +120 oF using the electric start at any possible humidity; +20 oF to +120 oF using the manual start at any possible humidity.

b. At altitudes up to and including 8,000 feet above sea level.

c. With the base of the set in planes from level up to 15 degrees from level.

d. With up to 5 inches of rain per hour impinging on the set at angles from the vertical up to and including 90 degrees from the vertical.

e. With up to 355 British thermal units (BTUs) per square foot per hour of solar radiation.

f. With a sand/dust particle concentration of up to 1,400 mg per cubic meter. Particle sizes shall range from less than 74 micrometers in diameter to 1,000 micrometers, with the bulk of the particles ranging in size from 74 to 350 micrometers.

g. With a steady wind speed of up to 73 feet per second and gusts up to 95 feet per second at a height of 10 feet above ground level.

h. With accumulations of ice glaze, freezing rain, and hoarfrost of up to 0.5 inch and up to a specific gravity of 0.9.

i. In a salt fog or sea-spray environment.

j. With fuels, lubricants, and coolants specified in 3.11.

3.8.2 Operating. Immediately after starting and with a 5 minute (maximum) warm-up period at no-load operation; the set shall operate without damage (see 6.3.2, 6.3.2.1, and 6.3.2.2) or failure (see 6.3.7.1, 6.3.7.3, and 6.3.7.4) at all loads, continuous and intermittent, up to and including rated load under any of the conditions or combinations of the conditions specified in 3.8.1, except that:

a. For the set rating of 3.0 kW at 1000 feet altitude and 107 oF:

1. Set rated load may be de-rated up to 3.33 percent for each 1000 feet above 1000 feet.

2. Set rated load may be de-rated at 1000 feet up to 1.00 percent for each 10 oF above 107 oF.

3. At 4000 feet and 95 oF, set de-rating shall not exceed

10.00 percent.

4. At 8000 feet and 95 oF, set de-rating shall not exceed

23.30 percent.

3.8.3 Stopping. After a normal start, the set shall stop (see 6.3.19) within 60 seconds after activation of any device intended to stop the set.

3.9 Life (endurance) requirements. The set shall operate for 1500 hours without critical failure (see 6.3.7.1) at all loads, continuous and intermittent, up to and including rated load under all of the conditions specified in 3.8.2. The set shall have a minimum life of not less than 6000 hours.

3.10 Not used.

3.11 Fuels and lubricants. No manual adjustment is allowed when changing fuel type. The set, while operating on Grade Low Sulfur No. 1-D, or Grade Low Sulfur No. 2-D diesel fuel conforming to Commercial Item Description (CID)

ASTM-D975; or JP-8 turbine fuel conforming to MIL-DTL-83133; or F-24 aviation turbine fuel conforming to AFLP-3747 (and CID ASTM-D1655) shall meet all requirements herein. The total particulate level of the fuel shall not exceed 20 mg/L. The engine shall operate on lubricating oil conforming to MIL-PRF- 2104 or MIL-PRF-7808 when temperatures are above -15 oF and MIL-PRF-46167 when temperatures are at or below +40 oF.

3.12 Other set requirements.

3.12.1 Overspeed. The set shall withstand engine operation at 110 percent of rated speed (see 6.3.15) for 5 minutes without damage (see 6.3.2).

3.12.2 Flexural vibration and critical speeds. The set shall be free from dangerous flexural vibrations (see 6.3.3) and dangerous torsional critical speeds (see 6.3.4) between the minimum low idle speed and 110 percent of rated speed (see 6.3.15).

3.12.3 Vibration stress. The set shall be capable of withstanding vibrational stresses without damage (see 6.3.2) during transportation and operational modes.

3.12.4 Maximum power. The minimum acceptable maximum power shall be 110 percent of rated load at 1000 feet elevation not to exceed 2.5 minutes. At elevations greater than 1000 feet, the maximum power shall not exceed the de-rating parameters specified in 3.8.2. Production sets shall have a maximum power of not less than 2.00 percent below the average maximum power measured for the PQT sets when corrected for the same conditions.

3.12.5 Fuel consumption. Fuel consumption of the production sets shall not exceed the average fuel consumption of the PQT sets by more than 5.00 percent under the same loads.

3.13 Transportability.

3.13.1 Lifting and tie-down provisions. Mechanical lifting and tie-down provisions shall be provided in accordance with MIL-STD-209, except as specified herein. Slinging and multipurpose tie-down provisions shall have a minimum inside clearance of 1.969 inches, and a maximum inside clearance of

2.169 inches. Slinging and multipurpose tie-down provisions shall have a minimum clearance from the set surface to the farthest inside edge of 1.969 inches and a maximum clearance from the set surface to the farthest inside edge of 3.969 inches. The identification of slinging, tie-down, or multipurpose provisions shall be in letters not less than 0.375 inch in height. The set, with fuel tank 1/4 full to full, with or without the battery shall remain within 15 degrees of level when lifted. Lifting provisions shall be marked "LIFT HERE," and tie-down provisions shall be marked "TIE-DOWN."

3.13.2 Rail tie-down procedures. The set shall be able to mount to a rail flatcar for shipment (transportation) using procedures and equipment typically provided for rail transport. Mounting of the sets shall be in accordance with standard loading and bracing methods as shown in Section 6 of the Association of American Railroads (AAR) "Rules Governing the Loading of Department of Defense Material on Open Top Cars."

3.13.3 Air transportability. The set shall not be damaged (see 6.3.2 and 6.3.2.1) by aircraft and helicopter transportation (see 6.3.1) and shall be transportable while facing forward, aft, and to either side.

3.13.3.1 Internal air transport. The lifting and tie-down provisions (see 3.13.1) shall meet the requirements of MIL-STD-209. The set shall be capable of being transported in a C-130 or larger aircraft and inside utility rotary wing aircraft while facing forward, aft, or to either side.

3.13.3.2 Military airdrop. The sets shall be capable of being platform mounted while facing forward, aft, or to either side. The sets must be deliverable by Low Velocity Air-Drop (LVAD).

3.13.4 Rail transport. The set while facing forward, aft, and to either side and the power plant assembly (see 3.19.4.2) while facing forward and aft shall be capable of being rail transported (see 6.3.13) on open top railcars without damage (see 6.3.2 and 6.3.2.1).

3.13.5 Utility vehicle and trailer transport. The set shall be capable of being transported by utility vehicle or trailer transportation (see 6.3.21) while facing forward, aft, or to either side without damage (see 6.3.2 and 6.3.2.1). The Road Transportability test shall be conducted in accordance with Appendix E.

3.13.6 Inclined transportation. The set shall be capable of being transported while in an operable condition but not operating, when inclined at any angle from horizontal to 25 degrees from horizontal in any direction, and with the fuel tank at any possible level from empty to full, with no spillage or seepage from the set or any of its components.

3.13.7 Forklift openings. Openings shall be provided in the skid base to permit insertion of forklift tines. Each opening shall be not less than eight 8 inches long and 2.5 inches in height and the openings shall be located such that the center of gravity of the set falls approximately midway between the centers of the forklift openings. The distance between the centers of the openings shall be a multiple of 2 inches but not more than 28 inches or less than 18 inches. The openings shall be reinforced and equipped with guides such that the set will not be damaged (see 6.3.2 and 6.3.2.1) when lifted by a forklift, the tines of which do not extend completely through the base. Each opening shall be marked "FORKLIFT HERE" in 0.75 inch minimum letter height.

3.13.8 Handling. The set shall have provisions such that six (6) soldiers can manually lift and transport the set. These provisions shall be located below the centerline of the set, and shall be suitable for use with personnel wearing arctic mittens and MOPP IV clothing. Handles shall be located so that six (6) personnel can lift and carry the set without interfering with one another. The handling provisions shall be within the set maximum dimension (see 3.19.1) when not in use. The handles must have a stop position perpendicular to the surface on which it is mounted, and be parallel to the ground when positioned for use. Any two (2) opposing handles shall be capable of supporting the weight of the set.

3.14 Storage. The set without packaging shall not be damaged (see 6.3.2 and 6.3.2.2) by storage at any possible humidity, in a salt fog environment, or by cold temperatures down to –60 oF.

3.15 Safety. The set shall meet the provisions of MIL-STD-882, paragraph

5.13 of MIL-STD-1472 (as specified in 3.26), and can use Requirement 1 of MIL- HDBK-454 for guidance. Exposed parts of such nature as to be a hazard to personnel shall be insulated, enclosed, or guarded without impairing the functioning of these parts.

3.16 Electromagnetic interference. The electromagnetic interference and susceptibility characteristics of the set shall not exceed the UM04 limits for class C2 equipment of MIL-STD-461.

3.17 Servicing, operation, and maintenance. The design and construction of the set shall permit routine service and maintenance under military field conditions. Any unscheduled maintenance which requires the removal of the set housing shall be validated before the set housing is replaced. Parts that require adjustment or servicing shall be capable of being adjusted or serviced by personnel wearing arctic clothing, and/or MOPP IV chemical, biological and radiological clothing. The set shall be capable of being started and operated by one operator under all conditions. Starting or stopping the set shall not require manipulation of more than one control or switch, except for the activation of the engine starting aid control device (3.36.1.7). Hardware, which requires torquing, shall be installed such that the nut, bolt, or screw head is accessible for torque wrench application. A spare fuse shall be stored and properly marked close to the location of the fuse it is a spare for. In assemblies where both a bolt and nut are used, the nut shall be accessible for torque wrench application. When test, measurement, and diagnostic equipment (TMDE) is required, TMDE shall be selected from the TMDE Preferred Items List.

Standard tools in the General Mechanic's Automotive Tool Kit (PN 5180-95-B48), Shop Equipment Automotive Maintenance and Repair (SC 4910-95-CL-A62), and the Standard Automotive Tool Set (SATS) (SC 4910-01-95-A81) shall be used for set maintenance. Servicing, operation, and maintenance requirements shall be met with the set on the ground or on the specified trailer mounted configuration (see 3.19.4). Design for maintainability shall comply with 3.26. Particular design attention shall be given to paragraph 5.9 (especially 5.9.10.3) of MIL- STD-1472 (captive fasteners) as specified in 3.26. Fasteners used for scheduled maintenance shall be visible to the maintainer. Fluid indicators shall be easily and readily accessible.

3.17.1 Maintainability requirements. Maintainability requirements shall be applicable to the generator set while operating on the ground or in the specified trailer mounted configuration (see 3.19.4).

3.17.1.1 Preventive maintenance. The minimum interval (hours of set operation) between scheduled preventive maintenance (checks and inspections) shall be 24 hours. Preventive maintenance actions shall include but not be limited to the following:

a. Inspecting for loose connections, leaks and cracks.

b. Checking and adding lubricating oil.

c. Draining of contaminants from fuel filters and water separators through drain valves.

d. Checking and servicing of the battery.

e. Checking and adding coolant if applicable.

3.17.1.2 Scheduled maintenance. The minimum interval (hours of set operation) between scheduled maintenance services (adjust and replace) shall be not less than 100 hours. Scheduled maintenance service intervals for the set life (see 3.9) shall be as recommended by the contractor. The maximum time for all scheduled maintenance actions at each scheduled maintenance interval, performed at intervals less than 2,000 hours, shall be 2 hours when conducted by one (1) person (MOS-91D). One (1) person shall be able to change the oil and oil filter within 20 minutes.

3.17.2 Maintenance ratio. The maintenance ratio (see 6.3.10) of the set shall not exceed 0.05 maintenance man-hours per operating hour for the combined organizational and direct support maintenance levels.

3.17.3 Diagnostic test points. The set shall include diagnostic test points as necessary to fully monitor and troubleshoot the set. All diagnostic test points shall be located in one easily accessible area inside the control panel. All test points shall be labeled and identified (see 3.42.3.9).

3.17.4 Engine/generator lifting attachments. A single lifting attachment shall be provided for removal of both the engine and generator. The lifting attachment shall withstand, without damage (see 6.3.2 and 6.3.2.1), a minimum of 3.5 times the weight of the lifted assembly. The inside dimensions of the lifting attachment shall permit passage of a two-inch diameter lifting device.

3.18 Interchangeability. All modes shall use the same engine, governing system, skid base, housing, frame, ac and direct current (dc) wiring harness, mounts, battery, battery charging system, fuel system, air filter, oil filter, fuel filter, muffler, and as many other common components as practical. All modes shall also be capable of being mounted on the applicable trailer (see 3.19.4).

3.19 Physical configuration.

3.19.1 Size. The maximum set dimensions shall be:

a. Length – 34.75 inches

b. Width – 27.80 inches

c. Height – 26.50 inches

3.19.2 Weight. The total operational weight (see 6.3.20) of the set shall not exceed 338 pounds.

3.19.3 Not used.

3.19.4 Trailers. Two (2) sets shall be capable of being operated and maintained as specified in this PD when mounted on the Light Tactical Trailer

(LTT).

3.19.4.1 Trailer interface. A four-hole bolt pattern shall be provided in the skid base of the set. The bolt pattern shall be located such that the longitudinal and lateral center of gravity of the set falls approximately between the centers of the bolt holes. The bolt holes shall be large enough to accommodate a half-inch diameter bolt.

3.19.4.2 Power plant (PP) assembly. Two (2) Mode III sets shall be mounted onto the specified trailer (see 3.19.4).

3.20 Load terminals and receptacles. The set shall be equipped with three ac output terminals. They shall be conspicuously marked "L1," "L2," and "N"; terminal "N" being neutral. The terminals shall be arranged in-line in the sequence "L1," "L2," and "N" when reading from left to right or from top to bottom. A fourth terminal, marked "GND,” shall be provided next to the three output terminals to serve as equipment ground for the set. The terminals shall be mounted adjacent to a corrosion resistant ground plane. The ground plane shall contain the "GND" terminal and be permanently connected to the skid base by means of a low impedance, corrosion-free connection. The mounting arrangement shall permit a removable, low impedance connection between the "N" and "GND" terminals. Terminal studs shall conform to drawing 30554 69-692 -6.

Terminals shall be rigidly mounted; studs shall not twist or turn in their mountings when hexagonal bar nuts are tightened. Terminals shall be readily accessible for connection of external output wires. All terminals shall be protected to prevent accidental contact. A non-conductive wrench suitable to tighten and loosen the hexagon bar nuts shall be provided with each set. It shall be attached to the set and shall be secured inside the set housing when not in use.

3.20.1 Not used.

3.20.2 Convenience receptacle. The set shall be provided with a convenience receptacle located near the control assembly. The receptacle shall be mounted on the exterior of the set, accessible without opening any housing access doors. The receptacle shall be connected in accordance with the National Fire Protection Association (NFPA) 70 for all set voltage connections.

The set convenience receptacle shall be a 120-volt, 15-amp, single-phase, duplex receptacle protected by a 10-amp ground-fault circuit interrupter (GFCI). The GFCI shall be mounted adjacent to the convenience receptacle. The convenience receptacle shall be equipped with separate spring-loaded (in the closed position), weatherproof covers.

3.20.3 Convenience receptacle overload protection. A 10-amp circuit interrupter shall be provided that prevents overload damage (see 6.3.2) to the convenience receptacle circuit. The circuit interrupter shall be integral with the ground-fault circuit interrupter (GFCI).

3.21 DC control power. All dc control devices shall be suitable for operation at 20 to 32 volts.

3.22 Circuit interrupter. A dust and water resistant circuit interrupter shall be provided and connected between the output load terminals and the bus.

It shall be a device constructed such that the main contacts close and open simultaneously through action of a common mechanism. It shall not be possible for any of the main contacts to remain closed while others are open.

Interrupting capacity of the main contacts shall be not less than eight (8) times rated current for the set. The circuit interrupter shall be located on the control panel side of the set.

3.23 Wiring. All wire shall be secured neatly into harnesses. Cable or wire run between parts that move relative to each other (as a result of vibration, adjustment, inspection, or as a matter of normal operation), shall be provided sufficient slack in the harness to allow repeated movement without bending or twisting to the point of damaging the wire in any manner.

Additional protection such as cable covers shall be provided. Wires shall not be spliced. All wiring harnesses shall permit ease of removal and replacement of components. Not more than four (4) terminal lugs shall be attached to any one (1) stud on stud-type terminal boards. Terminals on electrical components shall not have more than two (2) wires attached.

3.23.1 Wire and wire marking. Wire shall be multi-stranded copper conductor, flame retardant, moisture, heat, and oil resistant IAW either SAE AS22759/16, or as prescribed in the TDP. All wire shall be numbered for easy identification IAW drawing 30554 98-19633 and 30554 98-19592. The marking shall be permanently applied to the wire to withstand all specified operating conditions herein throughout the life of the set. Marking shall be every 3 inches along the entire length of the wire. All wire (except the battery cables, 3.30.7.2.2) shall have a color marking to indicate the type of current being carried by that wire, a “RED” color marking indicating dc and a “BLACK” color marking indicating ac. Wire coating material shall not be of the same color for that wire. Coding by color of wire is prohibited, except as otherwise specified herein.

3.23.2 Flexible cords and cables. Flexible Cords and cables shall have multi-stranded copper conductors, be flame retardant, moisture, heat, and oil resistant IAW either UL 62, SAE J1127, or as applicable and prescribed in the

TDP.

3.24 Grounding. All ac electrical components of the set shall be isolated from ground, except as otherwise specified herein. The equipment ground terminal (GND) shall be connected by a removable, low impedance, corrosion-free connection to the neutral output terminal "N" (see 3.20).

Direct current components shall not solely depend on chassis or case grounding to function except for the cranking motor (starter). A three-section ground rod conforming to type III, class B of A-A-55804 shall be provided for each set when specified (see 6.2). Ground rods shall be stored with the set.

3.25 Voltage reconnection method. A voltage reconnection method shall provide all specified output voltages.

3.26 Human factors engineering. The set shall be designed in accordance with criteria of design for Human Factors Engineering as described in MIL-STD- 1472. The set shall be transportable, operable, and maintainable during day and night by 5th percentile through 95th percentile soldiers when wearing the clothing which is appropriate to the environments described in 3.6 and 3.8.1, including Arctic and MOPP IV clothing and mittens. Particular design attention shall be given, but not limited to the following paragraphs of MIL-STD-1472: 4 (General Requirements), 5.1 (Control/Display Integration), 5.2 (Visual Displays), 5.3 (Audio Displays), 5.4 (Controls), 5.5 (Labeling), 5.6 (Anthropometry), 5.9 (Design for Maintainer), 5.13 (Hazards and Safety).

Specific citations of MIL-STD-1472 contained elsewhere in this PD shall not preclude this general requirement.

3.27 Skid base. The skid base shall extend horizontally beyond all components of the set. The skid base shall be provided with a method to drain spilled liquids from the interior of the set. There shall be at least a one-inch clearance between the lowest projection of the set and the bottom of the skid base. The set shall not move or "walk" when operating unrestrained, on a level concrete surface, under all operating conditions specified herein. The skid base shall be integral with the set housing.

3.28 Engine and generator mounting. Mounts shall be resistant to fuels, lubricants, and greases (see 6.3.9).

3.29 Housing. The set housing shall be removable to perform unscheduled maintenance actions including removal of engine, generator or other components.

The housing shall provide for access to the interior of the set, without removal of panels, as necessary to perform all preventative and scheduled maintenance service (see 3.17.1) actions and also permit replacement of the set battery while setting on the ground or mounted on the applicable trailer.

Hinged doors shall be self-supporting in the open position. The door swing for the hinged door shall not exceed 20 inches. The housing shall be permanently marked with a “CAUTION” against standing or storage of heavy objects on its top. The housing shall have drain holes to allow liquids to drain from within the housing.

3.29.1 Hinges and latches. Hinges or hinge pins shall be peened at the ends, to prevent workout of the pins. Latches shall require manual, not spring action, for closing. All parts of the latches having relative motion with each other shall be of corrosion-resistant metal. Access door latches (see 3.29) shall be flush mounted, non-key locking, dead bolt, and shall not require the use of tools for operation.

3.30 Engine. The engine shall have a minimum Continuous Duty Output rating corresponding to the applicable set load rating at all operating conditions specified herein up to and including 8,000 feet at 95 oF. The engine shall be protected against damage (see 6.3.2) resulting from overspeed conditions and shall prohibit overspeed in excess of 110 percent of rated speed.

3.30.1 Not used.

3.30.2 Lubricating system. The set shall meet all requirements herein using lubricants specified in 3.11. The lubricating system shall be provided with seals, gaskets, and bearing clearances to permit use of arctic lubricating oil conforming to MIL-PRF-46167. The lubricating system shall be compatible with MIL-PRF-21260 preservative oil. The oil temperature in the oil sump shall stabilize below the maximum temperature recommended by the engine manufacturer (248 oF) under full load at all conditions specified herein. At reduced loads, including no load, minimum oil temperature shall not be less than 80 oF. An oil-drain assembly shall be provided and installed in such a manner to allow complete drainage of the crankcase/oil-sump outside of the skid base. The oil drain shall be at least 3 inches above the bottom of the skid base. External piping, valves, fittings, and tubing of the lubricating system shall be disconnectable and easily accessible for maintenance. The oil-level bayonet gauge shall be marked to accurately indicate full and low oil-level, with the set in a level position. The bayonet gauge shall be placed in a readily accessible location. An integrated cap and dipstick shall be provided with the set. Marking shall be provided at the fill port in accordance with 3.26 and oil drain in accordance with 5.9.5 of MIL-STD-1472 (as specified in 3.26). The drain pipe shut-off valve shall be provided with a double-ended arrow showing direction of operation, labeled at each end to indicate the functional result.

3.30.3 Manual turning. Provisions shall be made to permit manual turning of the engine crankshaft and associated parts so that inspection and maintenance of parts requiring reference to the crank angle can be made.

Manual turning by barring on the flywheel ring gear, the generator coupling, or the generator fan is not permitted.

3.30.4 Exhaust system. Engine exhaust shall be located on the opposite end of the set from the control panel and as far away from the control panel as practical. Engine exhaust shall exit from the top of the set, in an upward direction, and after discharge shall not re-enter the set. Means to prevent rain from entering the engine exhaust system and the cooling air outlet shall be provided.

3.30.5 Not used.

3.30.6 Starting aids. Starting aids shall be compatible with the primary battery voltage. Reduced voltage type glow plugs or ether injection systems shall not be utilized. The starting aid system shall not be required for the set starting at temperatures at or above +20 oF.

3.30.7 Starting system. An electrical 24 VDC starting system shall be provided with the set. It is required that the set be provided with a manual starting system in addition to the electrical 24 VDC starting system. The electrical starting system shall not prevent starting with the manual starting system.

3.30.7.1 Manual starting system. The manual starting system shall be equipped to manually start the set without the use of any battery or similar electrical starting assistance either internal or external to the set. The manual pull start system shall have a means to automatically rewind the rope.

The manual starting system shall start the set at temperatures of +20 oF and above. The manual force required to start the set shall not exceed the requirements specified in 3.26 for female operators. The manual starting system shall be easily replaceable without the removal of the engine. The set shall meet all operational requirements with the battery removed.

3.30.7.2 Electrical starting system. The electrical starting system shall have a 24-volt (nominal) cranking system for starting and control power as described herein. The cranking system consists of a cranking motor, start solenoid, battery, battery retainer, slave receptacle, battery charging system, and sufficient relays, connectors, switches, and cable to make a complete system. The system shall have a negative ground. After starting, the set shall be capable of operating with the battery removed.

3.30.7.2.1 Battery. The set battery shall start and operate the set as specified herein on a battery conforming to the technical data package (TDP).

Batteries shall be furnished with the PQT sets. Batteries shall be furnished with production sets when specified (see 6.2). Insulated boots shall be installed over battery terminals. The battery shall have sufficient capacity to permit fulfillment of the following requirement under all conditions between 120 oF and -25 oF ambient temperatures:

After two consecutive cranking cycles, each comprising 15 seconds of continuous cranking, on an inactive set (engine fuel supply shut-off), followed by a 5-second rest period, the battery shall have sufficient reserve to permit starting (see 3.8.1) the set.

3.30.7.2.2 Battery cable. The positive cable shall have a non-conductive red sleeve at both ends. The negative cable shall have a black non-conductive sleeve on both ends. Battery terminal connectors shall be provided on one end of each cable. A red non-conductive protective cover shall be provided on the positive battery terminal connector. The battery cable shall be safely secured within the set and protected from damage when it is not in use. Battery cable shall be marked to indicate polarity.

3.30.7.2.3 Polarity reversal. Disregarding use of the NATO slave receptacle, the set shall not be damaged (see 6.3.2) in any manner, in the event polarity of internal battery cables is reversed. It shall not be possible to crank the set with battery polarity reversed.

3.30.7.2.4 Battery retainer. Means shall be provided to retain the battery (see 3.30.7.2.1) within the set during all transportation and handling and shall be of a type that will permit easy removal and installation of the battery. In addition, the battery shall be protected from external environmental conditions. The retainer shall be resistant to battery electrolyte. Means shall be provided to allow drainage of spilled electrolyte out of the set without contact with any set component except the retainer. The battery shall be located, or venting provided, so that charging vapors will not enter the generator or any of the electrical accessories. The battery retainer and battery shall be such that access to the battery for maintenance, removal and test is in accordance with figure 45 of MIL-STD-1472 (as specified in 3.26).

3.30.7.2.5 Cranking motor (starter). Means shall be provided to prevent starting of the motor and engagement of the drive mechanism during running of the set or when coming up to rated speed after the cranking motor disengages.

The cranking motor shall be compatible with the engine and sized properly to start the set under all operating conditions specified herein and without interference of other set components. The cranking motor shall be supplied with removable wire(s) of sufficient size to carry the cranking current. The positive terminal where the starting current flows shall be directly connected to the set battery and shall be protected by a terminal insulator. The terminal insulator shall not come into contact with any feature of the muffler.

If applicable, the negative terminal or housing where the starting current flows shall be directly connected to the set battery. If the housing of the cranking motor serves as the negative terminal when bonded to the engine, then the engine shall be directly connected to the negative terminal of the battery by a removable wire.

3.30.7.2.6 NATO slave receptacle. A receptacle conforming to drawing 19207 11674728 with cover shall be mounted in a mechanically protected position on the control assembly end of the set, and shall be connected in parallel with the battery, using wire capable of carrying the cranking motor starting current.

3.30.7.2.7 Battery charging system. The battery charging system shall have temperature compensating characteristics compatible with the battery. The battery charging system shall not be damaged by continuous application of a short or open circuit to its output. Operation of the set without a battery shall not damage (see 6.3.2) the set or any of its components. The battery charging system shall be capable of charging and maintaining the battery after the starting cycle in 3.30.7.2.1 in a state of full charge after 4 hours of operation in addition to providing control power at any load.

3.31 Fuel system. The fuel system shall consist of a fuel tank, pump(s), filters, auxiliary fuel line, auxiliary fuel in-line strainer, external connections, and other devices as required achieving a complete system that can operate on the fuels specified in 3.11 and meeting the requirements herein.

The fuel system, including piping, valves, filters, and connections shall prevent air from entering the system and shall prevent fuel flow from being restricted when the fuel is supplied from the set fuel tank or from an external fuel supply. The system shall not become air bound (resulting in any change in frequency outside the permissible variation under constant load) when the auxiliary fuel supply hose is removed for 3 minutes and then reinserted into an external fuel supply while the set is operating at rated load. A means shall be provided to bleed air from the fuel system. The set shall be capable of operating from a fuel source either 6 feet above or below the set inlet connection when connected through the auxiliary fuel hose specified in 3.31.6.

The fuel system design shall prevent fuel overflow when the set is being operated from the auxiliary fuel connection and prevent siphoning when the set is stopped. Refueling with the set operating shall not adversely affect set operation. A label stating the allowable fuel types shall be located adjacent to the fuel fill opening. No copper, zinc, or vanadium alloys shall be in contact with the fuel except for the brass flare fittings required herein, internal parts of the auxiliary fuel transfer pump, engine fuel solenoid valve assembly and auxiliary strainer, engine injector gasket, and engine fuel system fittings including related gaskets. The fuel system components shall have inlet and outlet connections permanently marked.

3.31.1 Fuel tank. The fuel tank shall have a capacity such that the set, when the set skid base is level to 15 degrees from level, is capable of operating for 8 hours at rated load (see 6.3.14) on all fuels specified in 3.11 without refueling. The tank filler neck shall be made from conductive material, accommodate a 1 1/4-inch diameter fuel filler nozzle, and have provisions for closure with a filler cap. The tank filler neck shall be located in such a manner that the filler cap is within the exterior profile of the housing, but is outside the housing. The filler cap shall be vented, include provisions to prevent entry of rain and attached to the set with a link-type chain of sufficient length to permit removal for refueling of the set. The fuel filler neck shall have a removable fuel strainer attached to the filler with a link-type chain of sufficient length to permit removal for cleaning. The set fuel tank, filler neck, fuel strainer, and other fuel system components that may accumulate static charge shall be adequately bonded and grounded to the set frame to provide for static charge bleed off. The inlet of the fuel pickup shall not be less than 1/2-inch from the bottom of the fuel tank and the inlet end of the fuel pickup shall be cut off at an angle or vee.

Plastic threads shall not be used for fuel line connections. A fuel drain and drain valve shall be located for emptying any fuel and sediment in the tank into a container without requiring the removal of the tank from the set. The fuel drain shall terminate with a brass, external thread, 1/2 - 20 SAE J514 flare fitting, with captive cap. The tank shall have means provided for maintenance of fuel tank components without removal of other set components.

The tank shall be located within the set dimensions. Filling the tank shall be accomplished without the opening of any door or panel. The fuel filler neck shall be positioned to prevent spillage of fuel onto the set and to prevent spills or overflow to run into the engine, exhaust, or electrical equipment during filling from a 5-gallon fuel-can spout. Location of the tank shall permit filling the tank and operation of the set when the set is inclined in planes from level to 15 degrees from level.

3.31.2 Auxiliary fuel connection. The fitting for connection of the auxiliary fuel line between the set and the external fuel source shall be a brass, external thread, 1/2 - 20 SAE J514 flared fitting, with captive cap and be located within the profile of the housing, but be outside the housing. The fitting shall be labeled "EXTERNAL FUEL SUPPLY.”

3.31.3 Fuel level indicator. The fuel level indicator (see 4.8.2.11) shall be located within the set dimensions (see 3.19.1) and shall be readable without opening any door or…