PD11WRGRVEA02_RevA.doc

WARNER ROBINS AIR LOGISTICS CENTER

PURCHASE DESCRIPTION

SUPPORT EQUIPMENT &

PD11WRGRVEA02 Rev A

VEHICLES DIVISION

CAGE 98752

GRVEA

17 FEB 2011

PD11WRGRVEA02

COMPRESSOR, AIR, DIESEL ENGINE DRIVEN, PORTABLE,

WHEEL MOUNTED, 125 CFM, 100 PSI

1. SCOPE

1.1 Scope. This purchase description covers the requirements for the design and construction of an air compressor unit that can supply a minimum of 125 cubic feet per minute (cfm) at 100 pounds per square inch (psi). The compressor unit shall be a wheel mounted, diesel engine driven, rotary screw air compressor.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C

Colors used in Government Procurement

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-0053030B

MIL‑DTL‑25959F

Primer Coating, Epoxy, Water Reducible, Lead and

Chromate Free

Tie Down, Tensioners, Cargo, Aircraft

DEPARTMENT OF DEFENSE STANDARDS

DEPARTMENT OF DEFENSE HANDBOOKS

(Copies of these documents, except for MIL-HDBK-1791 C-17 Appendix, are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. A copy of MIL-HDBK-1791 C‑17 Appendix can be obtained from the Procuring Contracting Officer (PCO) or requested by contacting Air Transportability Test Loading Agency (ATTLA) at 937-255-6296.)

COMMERCIAL ITEM DESCRIPTIONS

A-A-59565

Hose, Rubber, and Hose Assemblies, Rubber, Pneumatic

(Yarn or Fabric Reinforced)

AIR FORCE DRAWINGS

50C24033

Coupling-Male, 12-inch Air Duct

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

AMERICAN WELDING SOCIETY (AWS)

(Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami FL 33126.)

National Electrical Manufacturers Association (NEMA)

NEMA MG 1

Motors and Generators (Applications for copies should be addressed to NEMA, 1300 North 17th Street, Suite 1847, Rosslyn VA 22209, www.nema.org.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE AS7365

Duck Assembly, Ground, Conditioned Air, Metallic

Reinforced, Low Pressure, 350 ºF

SAE AS8090

Mobility, Towed Aerospace Ground Equipment, General

Requirements For (Application for copies should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale PA 15096.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), 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 Preproduction testing. When specified (see 6.2), two samples shall be subjected to Preproduction Testing in accordance with 4.2.

3.2 Description. This air compressor unit shall be a two-wheel mounted, diesel engine driven, air compressor that supplies compressed air at 125 cfm and 100 psi continuously. The compressor unit shall consist essentially of a rotary screw type. The compressor unit shall be equipped with a receiver tank to accomplish the cfm and psi identified within this paragraph. The compressor unit shall be designed for mobile uses in shops, hangers, garages, and paint shops. The compressor unit is intended to supply air, but it is not intended for use as a source of breathing air.

3.3 Design and construction. The compressor unit shall be designed and constructed so that no parts will work loose in service. They shall be built to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. They shall be weatherproof and designed to prevent the intrusion of water and sand into critical operating components.

3.3.1 Dimensions and weight. The dimensions of the compressor unit shall not exceed:

Length

140 inches Width

70 inches.

Height

62 inches.

Weight

2,200 pounds.

3.3.2 Housing. The compressor unit shall be fully enclosed in a lightweight, constructed cabinet. A suitable housing shall be provided to enclose the engine, receiver, and instrument panel(s). Housing and panels shall be no less than 0.0625 inch thick. Supporting members and braces shall be furnished as required. The housing shall be sufficiently rigid to support 300 pounds load applied to any single one square foot area on the top of the housing. The housing shall include hinged access openings to the fuel cap, engine, air end, and instrument panels(s). Access panels(s) shall be equipped with devices to hold the panel(s) in an open position and clamps or latches to retain the panel(s) in the closed position. Fenders shall be able to withstand a load of at least 175 pounds (lbs) without permanent deformation. The cabinet shall be integrally mounted on a wheeled chassis.

3.3.3 Mounting/chassis. The compressor unit shall be a single axle, double-wheel unit. The complete compressor unit shall be securely mounted onto a trailer-type undercarriage equipped with parking brakes. Parking brakes shall be capable of holding the unit in a stationary position on a 15 degree angle. Parking brake lever handle shall be mounted in a horizontal or up to 45 degree downward position mounted either on the side of the unit or centered between the front drawbar and shall be reachable by the operator while maintaining control of lunette. All brake cabling shall be fabricated to the current material and technology to minimize water intrusion and rusting of the cables. The compressor unit shall be equipped with towing tongue and drawbar lunette-coupler. The lunette eye shall be rated at 30,000 lbs minimum. Total weight of the drawbar (towbar) shall not exceed 50 lbs.

3.3.4 Pivoting front landing wheel. The pivoting front landing wheel shall have a sealed bearing and be fully retractable, fully swiveling, and adjustable. The pivoting front landing wheel material shall be suitable for use on hard surface areas and gravel roads. The pivoting front landing leg with wheel shall be of the bolt-on type and not of the remove-by-pin type.

3.3.5 Tires. Tires shall be of rated-capacity at least equal to the load imposed on each tire. Tires shall be size 6.90 x 9, and shall be mounted on split rim assemblies. Tires shall not touch fenders when making turns.

3.3.6 Mobility. The compressor unit shall be in accordance with SAE AS8090 for Type II, Group A mobility. The compressor unit shall provide for stable towing and positioning, preclude “weaving”, and allow for stable movement on unimproved surfaces. It shall be towable at speeds up to 25 miles per hour (mph) over paved highway, speeds up to 15 mph over gravel roads, and speeds up to 8 mph over rough terrain.

3.3.7 Tilted operation. The compressor unit shall be capable of operating satisfactorily when its normal operation plane is at an angle of 15 degrees in any direction from true horizontal. The compressor shall be capable of operating continuously at rated capacity for not less than 30 minutes when tilted in any position at an angle of 15 degrees from the horizontal. The compressor shall be capable of standing continuously for not less than 2 hours in a 15 degree tilted position without any evidence of leaks or spills or reduced performance upon standing in this position.

3.3.8 Control panel. The compressor unit shall have all operating controls with an hour meter and gages on the control panel with each clearly marked. Control panel shall be illuminated for night operation. Users shall not have access to make maintenance adjustments to components on control panel.

3.3.8.1 Control panel door. Step-by-step operating instructions, for start-up, operation, and shut-down of the compressor unit, shall be mounted on the control panel door for viewing by the operator before and/or during operation. The operating instruction shall be located in such a manner as to be readily visible to the operator during those actions.

3.3.9 Accessibility. All working parts of the various sub-assemblies of the compressor shall be accessible through convenient doors or removable panels. The doors shall be large enough to allow maintenance and using personnel access inside the cabinet while wearing arctic gloves or Mission-Oriented Protective Posture (MOPP) IV protection gear. Controls or control panels shall be accessible through convenient doors. Access doors, which could cause injury to the operator or other damage to the compressor by inadvertent closing, shall be provided with safety links or be otherwise locked in the open position.

3.3.10 Manifold and service outlet. The air receiver discharge line shall be equipped with an air service manifold having two individual controlled service outlets with standard universal type, quick disconnect, pneumatic hose couplings. The air service manifold shall be fitted with 3/4 (three-fourth) inch service outlets. The outlets shall be equipped with lever-handle, plug-type air cocks and couplings conforming to a universal-type quick disconnect for a 3/4 inch service outlet. The compressor unit shall be equipped with a check valve and a manual shutoff valve installed in the air line between the receiver and the manifold outlet to prevent reverse flow of air into the receiver.

3.3.11 Hose reel. The compressor shall be provided with two automatic retractable hose reels capable of locking in place. The hose reels shall be contained within an enclosed design. The reels shall have the capacity for and be equipped with not less than 50 feet of 3/4 (three-fourth) inch air hose conforming to Commercial Item Description A-A-59565. The air hose shall be attached to the reel by a coupling conforming to a universal-type quick disconnect for a 3/4 inch service outlet. The fittings for attaching the hose shall be located so that when the hose is attached and spooled back onto the reel, no sharp bends shall occur in the hose. The reels with automatic hose retraction capability shall be mounted so they are accessible and shall not reduce the ground clearance of the unit.

3.3.12 Pressure regulator. The compressor unit shall be provided with a pressure regulator designed to regulate the outlet pressure within the range of from 0 to 100 psi. The regulator shall regulate the outlet pressure at the desired pressure within + 5 percent. The outlet hose connection shall be on the outlet side of the pressure regulator.

3.3.13 Pressure servicing system. The components of the pressure servicing system shall consist of a regulator, regulator isolation valve, servicing gages, adjustable relief valve, servicing hose, servicing valves, bleeder valve, and a hose reel.

3.3.14 Materials, protective coatings, and finish.

3.3.14.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials shall be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. However, used, rebuilt, or refurbished items shall not be provided.

3.3.14.2 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the item shall not be used or shall have means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used. Fasteners, handles, and fittings used in the assembly of the item shall also be primed and painted.

3.3.14.2.1 Surface preparation and pretreatment. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications. Structures shall be cleaned, degreased, and scuffed or blasted prior to priming; primer shall be applied before any oxidation or rusting occurs. Aluminum surfaces shall have MIL-DTL-81706, Type II, Class 1A, and MIL‑DTL‑5541, Type II, Class 1A, chemical conversion coating applied in accordance with the manufacturer’s directions prior to priming.

3.3.14.2.2 Primer. Raw metal edges, to include fastener and drain holes, shall be coated with primer before applying topcoat.

3.3.14.2.2.1 Ferrous surfaces. Ferrous structures and surfaces shall be primed with a water reducible zinc rich primer in accordance with MIL‑PRF‑26915, Type II, Class B; this shall be followed, within four hours, by a coat of MIL‑DTL‑0053030 intermediate primer in a wet-to-wet primer application. This two part primer system shall yield a dry-film thickness of 2.0-2.5 mils for the zinc primer and 0.9 to 1.1 mils for the intermediate primer. The two-primer system shall be allowed to dry and fully cure in accordance with the primer manufacturer's directions prior to top coating.

3.3.14.2.2.2 Aluminum and mixed aluminum and ferrous surfaces. Aluminum and mixed aluminum and ferrous structures and surfaces shall be primed with an epoxy primer, Type II, Class N of MIL-PRF-23377. This single part primer system shall yield a dry-film thickness of 0.6 to 0.8 mils.

3.3.14.2.3 Topcoat. Topcoat shall be polyurethane in accordance with Type II, Class H of MIL‑PRF‑85285. Neither Chemical Agent Resistant Coating (CARC) nor powder coating shall be used. Topcoat shall be applied to a dry film thickness of 1.6 to 2.4 mils in all instances, regardless of the primer system utilized. The coating shall be free from runs, sags, orange peel, or other defects.

3.3.14.3 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotively compatible abutting surfaces is acceptable. The use of dissimilar metals only when separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

3.3.14.4 Finish. The exterior finish color of the air compressor unit shall have a gray finish color, Color number 26173 of FED-STD-595.

3.3.14.5 Fluid traps and faying surfaces. There shall be no fluid traps on the compressor unit. Faying surfaces of all structural joints, except welded joints, shall be sealed to preclude fluid intrusion.

3.3.14.5.1 Ventilation. Ventilation shall be sufficient to prevent moisture retention and buildup.

3.3.14.5.2 Drainage. Drain holes shall be provided to prevent collection or entrapment of water or other unwanted fluid in areas where exclusion is impractical. All designs shall include considerations for the prevention of water or fluid entrapment and ensure that drain holes are located to effect maximum drainage of accumulated fluids. The number and location of drain holes shall be sufficient to permit drainage of all fluids when the unit is in a 15 degree incline in any plane. The minimum size of the drain holes shall be 0.25 inch.

3.3.15 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130. Markings shall be applied with decals and shall be 1-inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than ½-inch high. Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of FED-STD-595, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of FED-STD-595. The center of gravity of the compressor unit shall be stenciled on the unit within 1.0 inch of the calculated center of gravity.

3.3.16 Identification and information plates.

3.3.16.1 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the compressor unit in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). The compressor unit and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a bar code and human readable markings.

3.3.16.2 Transportation data plate. A transportation data plate shall be securely attached to the compressor unit in a readily accessible location. The plate shall contain at least the following information:

a. Side and rear silhouette views of the compressor unit.

b. Horizontal and vertical location of the center of gravity of the compressor unit in air transportable configuration, marked on the silhouette views.

c. Shipping weight.

d. Loading cubage.

e. Overall height, width, and length.

f. Front and rear axle loads.

g. Tie down information.

3.3.17 Safety.

3.3.17.1 System safety. The design of the compressor unit shall not contain any system safety mishap risk categories greater than low as defined in Table A-IV of MIL-STD-882.

3.3.17.2 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard.

3. 3.17.3 Foreign object damage (FOD). All loose metal parts, such as pins or connector covers, shall be securely attached to the compressor unit with wire ropes or chains. "Dog tag" style beaded chains shall not be provided. Removable panels, if provided, shall be attached with captive fasteners. Tire valve stem caps shall be made of plastic.

3. 3.17.4 Sound level. The noise produced by the compressor at the loudest operational mode shall not exceed 85 decibels (dB)(A) when measured at 24 feet (7.3 meters) from the perimeter of the compressor and at 4 feet (1.2 meters) above the ground.

3.3.17.5 Electrostatic discharge (ESD). The design of the compressor unit shall preclude equipment damage due to ESD, protect personnel from electrical shock due to static charging, and prevent ignition of explosive atmospheres due to sparking.

3.3.17.6 Surfaces. All hot surfaces of the compressor unit, including exhaust pipes and other lines which may be subject to high temperatures, exposed to contact by personnel, or which create a fire hazard, shall be fully guarded or insulated. Exhaust from the engine shall be directed upward away from personnel so that it does not endanger personnel and it precludes the possibility of exhaust entering into the compressor unit inlet. Electrical equipment, wires, and connectors shall be effectively guarded or insulated to protect all persons and objects from electrical shock hazard. Nonfunctional sharp edges, projecting points and excessive length of fastening devices shall be avoided. The exhaust outlet opening shall be protected with a rain guard.

3.3.17.7 Safety shutdown. The compressor shall be equipped with a manual emergency stop in addition to a safety shutdown system designed to automatically stop the compressor unit. The emergency stop shall be positioned in a recessed or protected manner as to prevent personnel from inadvertently engaging it.

3.3.18 Human engineering. The compressor unit shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of arctic mittens and MOPP Level 4 Chemical Warfare Gear.

3.3.19 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins, lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial components. Tapped aluminum threads shall have a minimum thread engagement of at least two times the nominal fastener diameter.

3.3.20 Welders and welding. All welders shall be certified to weld in accordance with AWS D1.1 and AWS D1.2. The contractor shall make available to the Government certifications for all welders being utilized on the compressor unit. Welding procedures and all welding on the compressor unit shall be in accordance with AWS D1.1 and AWS D1.2. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings.

3.3.21 Service life. The compressor unit shall be designed for a minimum service life of 15 years.

3.4 Environmental conditions.

3.4.1 Operating temperature range. The compressor unit shall be capable of operating in ambient temperatures ranging from -40º F to 140º F.

3.4.2 Storage temperature range. The compressor unit shall be capable of being stored in ambient temperatures ranging from -55º F to 155º F.

3.4.3 Precipitation.

3.4.3.1 Rain. The compressor unit shall be capable of storage and operation during rainfall of 5-inches per hour for three consecutive hours and 10-inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with 6-inches of rain per hour impinging on the compressor unit at angles from vertical to 45°.

3.4.3.2 Snow. The compressor unit shall be capable of storage and operation during accretion of wet snow up to 2-inches per hour for at least 12 hours on exposed horizontal surfaces.

3.4.3.3 Ice. The compressor unit shall be capable of storage and operation with ice accretion up to 1.5-inches on exposed horizontal surfaces. An operator may use an ice scraper for five minutes during the start-up process.

3.4.4 Solar radiation. The compressor unit shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments.

3.4.5 Fungus. All materials used in the compressor unit shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The compressor unit shall be suitable for operation and storage in conditions encountered in a tropical environment.

3.4.6 Salt fog. The compressor unit shall be capable of storage and operation in high temperature, high humidity, salt laden, sea coast environments without damage or deterioration of performance.

3.4.7 Sand and dust. The compressor unit shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance.

3.5 Transportability.

3.5.1 Surface transportability. The compressor unit shall be transportable via all modes of surface shipment (highway, rail, and water) in accordance with MIL‑STD‑1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport, except that design for rail impact testing (see 5.2.5 of MIL‑STD‑1366) is not required.

3.5.2 Air transportability. The compressor unit shall be transportable on C-5, C-17 and C-130 aircraft. Design criteria can be found in MIL-HDBK-1791. In all air transport configurations, the compressor unit shall be capable of being restrained and withstanding, without loss of serviceability, 2.0 G up and 4.5 G down accelerations, and shall be capable of being restrained and withstanding, without loss of structural integrity, 3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations. The compressor unit shall be equipped with pressure relief devices or configured for air transport to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure. The compressor unit shall roll on and off the aircraft, negotiating the required maximum ramp angles without shoring.

3.5.2.1 Tire pressure. Tire pressure shall not be reduced for air transport. Tire pressure shall not exceed 100 psi.

3.5.2.2 Winch points. Winch points shall be provided at the front and rear of the compressor unit for aircraft loading using the aircraft’s winch.

3.5.2.3 Equipment removal and reconfiguration. Preparation for air transport shall take no more than 4 man-hours and restoration to operating configuration shall take no more than 4 man-hours for 2 persons using common hand tools (see 6.3.1). All equipment removed shall be stored on the compressor unit; caps and plugs shall permit moving and storage in transport configuration.

3.5.3 Tie downs. The compressor unit shall be symmetrically restrained during air and ground transport. Tie down points shall be rated at a minimum of 25,000 pounds, marked for capacity, with a clear opening compatible with MIL‑DTL‑25959 and MIL‑PRF‑27260 tie down devices. Each end of each tie down device shall terminate at a tie down point and not pass through any other tie down point. There shall be no interference between tie down devices and the compressor. The tie down provisions shall be in accordance with 4.1 through 4.12 of MIL-STD-209.

3.5.4 Lifting provisions. The compressor unit shall be equipped with sufficient attachment points so located that it can be lifted by crane; each attachment point shall be marked "Lift Point". The lifting provisions shall be in accordance with 5.1 through 5.1.4 of MIL-STD-209.

3.6 Maintainability. The compressor unit shall be designed for maintainability in accordance with 5.9 through 5.9.18 of MIL‑STD‑1472; forces shall not exceed those specified for both males and females.

3.6.1 Preventive maintenance. The recommended preventive maintenance interval (PMI) shall be at least 720 operating hours. Preventive maintenance tasks shall not require more than 8 man-hours.

3.6.2 Inspection and servicing provisions.

a. Routine servicing tasks and pre-use inspections shall require no hand tools.

b. Drain plugs and filters shall be directly accessible and oriented to have unimpeded drainage to a catch pan.

c. The compressor unit shall be designed with maximum usage of sealed lifetime lubrication bearings.

d. The compressor unit shall be designed so the correct oil and coolant levels can be checked.

3.6.3 Relative accessibility. Critical items that require rapid maintenance shall be most accessible. When relative criticality is not a factor, items that require the most frequent access shall be most accessible. High failure rate items shall be accessible for replacement without moving non-failed items.

3.6.4 Error-proof design. The design of the compressor unit shall incorporate error-proofing in equipment mounting, installing, interchanging, connecting, and operating.

a. Equipment shall include physical features (for example, supports, guides, size, or shape differences, fastener locations, and alignment pins) that prevent improper mounting. In the absence of physical features, equipment shall be labeled or coded to identify proper mounting and alignment.

b. Equipment that has the same form and function shall be interchangeable throughout a system and related systems. If equipment is not interchangeable functionally, it shall not be interchangeable physically.

c. Connectors serving the same or similar functions shall be asymmetrically designed where possible to preclude mismating or misalignment.

d. Design, location, procedural guidance, and suitable warning labels shall be provided to prevent damage to equipment while it is being handled, installed, operated, or maintained.

3.6.5 Special tools. The design of the compressor unit shall minimize the requirement for special tools (see 6.3.2). All special tools shall be provided with, and stored on, the compressor unit.

3.6.6 Diagnostic software. A copy of any diagnostic software required or recommended for maintaining the compressor unit shall be provided with each compressor unit on CD‑ROM or DVD‑ROM.

3.7 Performance. The compressor shall be capable of compressing and delivering 100 cubic feet per minute of free air at a rated operating pressure of 125 pounds per square inch gauge (psig) under the following atmospheric conditions:

a. 14.696 pounds per square inch absolute (psia) (sea level, 29.92 in mercury Hg) b.

72 (F c.

0 - 5 % humidity

3.8 Endurance. The compressor shall be designed for continuous operation for a minimum of 240 hours under the conditions specified herein.

3.9 Engine and related equipment. The compressor unit shall be equipped with a diesel engine. Consistent with the requirement to operate on fuels containing over 15 parts per million (ppm) sulfur, the engine shall be certified to comply with the Environmental Protection Agency (EPA) non-road diesel engine emission requirements at the time of engine manufacture.

3.10.1 Engine starting system.

3.10.1.1 Starter. The engine shall be equipped with a 12-volt DC electric starter.

3.10.1.2 Engine starting aids. The engine shall start within 15 seconds cranking in any ambient temperature within the required operating range of the compressor unit. Installed glow plugs, fluid starting aids, and heat from the winterization system (see 3.11.3) may be used prior to and during the start period to facilitate engine starting under the following conditions:

TABLE I. Engine starting aids.

3.10.2 Engine air intake system. The engine air intake system shall be in accordance with 3.13.1.4.3 of SAE ARP1247. The inlet shall not draw air from directly beneath the compressor unit and shall not be located near the cooling system air outlet nor the engine exhaust outlet. Joints shall be minimized between the air filter outlet and the actual engine air inlet and shall be designed to ensure no leakage of unfiltered air into the engine. A differential pressure air filter service indicator shall be provided.

3.10.3 Engine cooling system. The engine cooling system shall be in accordance with 3.13.1.4.2 of SAE ARP1247. Silicone radiator and heater hoses, constant-torque clamps, a coolant filter, and a coolant recovery system shall be provided. Engine coolant shall be in accordance with A‑A‑52624, Type I, and of adequate strength to provide protection to -40ºF. The engine out (top of radiator) coolant temperature shall not exceed 210° F or the engine manufacturer’s recommendations.

3.10.4 Engine lubrication system. The engine lubrication system shall be designed so that the compressor unit can be operated on a 15º incline in any plane.

3.10.4.1 Engine oil. The engine shall be compatible with Grade 15W40 of MIL‑PRF‑2104 from 0° F to 140º F. Oil pre-heat for operation below 0° F is allowed. The engine shall be compatible with arctic engine oil in accordance with MIL‑PRF‑46167 from -40ºF to 60° F.

3.10.4.1.1 Engine oil operating temperature. The engine oil sump temperature shall not exceed 250° F or the engine manufacturer’s recommendations at any operating condition.

3.10.4.1.2 Engine oil consumption. The engine oil consumption shall not exceed 0.0035 pounds per brake horsepower-hour (lbs/bhp-hr) under any operating condition.

3.10.4.2 Engine oil filter. The engine oil filter shall be in accordance with 3.13.1.4.4 of SAE ARP1247.

3.10.5 Exhaust system. The exhaust system shall be constructed of stainless steel. The muffler(s) shall be constructed of aluminized steel or stainless steel. Exhaust system outlet(s) shall be directed away from personnel accessing any control panel or equipment compartment and the engine air intake, and shall not be directed toward the ground.

3.10.6 Engine fuels and fuel system.

3.10.6.1 Engine operating fuels. The following shall be standard operating fuels:

a. 1‑D S15, 1‑D S500, 1‑D S5000 in accordance with A‑A‑52557 and ASTM D975, below 60° F ambient air temperature.

b. 2‑D S15, 2‑D S500, 2‑D S5000 in accordance with A‑A‑52557 and ASTM D975, above 32° F ambient air temperature.

c. JP‑5, in accordance with MIL‑DTL‑5624, -40º F to 140º F ambient air temperature.

d. JP‑8, in accordance with MIL‑DTL‑83133, -40º F to 140º F ambient air temperature.

e. TS‑1 in accordance with GOST 10227‑86 with JP‑8 additives, -40º F to 140º F ambient air temperature.

3.10.6.2 Engine emergency fuels. The following shall be emergency fuels:

Jet A, Jet A1 in accordance with ASTM D1655-05, all ambient temperatures.

Note: Jet A and Jet A1 may contain corrosion inhibitor/lubricity improver and icing inhibitors which shall result in properties equal to JP‑8.

3.10.6.3 Engine fuel consumption. When operating on JP-8, the engine shall meet or better the following fuel consumption at full rated load:

a. Under 20 bhp rated engine, 0.500 lbs/bhp-hr brake specific fuel consumption.

b. Over 20 bhp rated engine,

0.380 lbs/bhp-hr brake specific fuel consumption.

3.10.6.4 Fuel system. The fuel system shall be in accordance with 3.13.1.5.1 through 3.13.1.5.11 of SAE ARP1247 except as otherwise specified herein. The fuel system shall be constructed of materials which are compatible with the fuels listed in 3.10.6.1 and 3.10.6.2. Copper shall not be used in the fuel system. The fuel system shall be equipped with a fuel shut-off valve(s) to prevent continuous spillage when fuel lines are disconnected for service.

3.10.6.4.1 Fuel priming pump. The compressor unit shall be equipped with an electric fuel pump in addition to the mechanical fuel pump. The electric pump shall be used as a priming pump capable of re-priming the engine fuel system following fuel exhaustion.

3.10.6.4.2 Fuel filters. Primary and secondary fuel filters and a heated fuel/water separator shall be provided. The fuel/water separator shall include a water coalescer and a drain valve that is readily accessible by an operator or a mechanic. A combination fuel filter and fuel/water separator may be provided. Fuel filter elements shall be easily replaceable by a mechanic using nothing more than common hand tools (see 6.3.1) without loss of engine prime.

3.10.6.4.3 Fuel tank. The fuel tank shall be in accordance with 3.13.1.5.5 through 3.13.1.5.9 of SAE ARP1247. The tank shall be designed so that the compressor unit can be operated on a 15º incline in any plane. The tank shall be provided with corrosion protection and baffles. A 0.25- to 0.375-inch nominal drain valve shall be provided for emptying fuel and sediment into a container underneath the compressor unit without removal of the tank or any other major component. The fuel tank shall have a fuel fill opening of not less than a three inch inside diameter and shall be designed to drain fuel spillage overboard for collection outside the compressor unit. The fuel cap shall be equipped with a retention device to prevent loss and FOD. The fuel fill opening, fuel cap, and fuel cap retention device shall be fabricated from non-sparking material.

3.10.6.4.4 Fuel tank capacity. The fuel tank shall be designed to provide enough fuel for continuous operations for a minimum of 8 hours. The tank shall be equipped with baffles, a replaceable drain, and a non-electric fuel indicator. Fuel tank shall be manufactured to prevent failure from corrosion or cracking from fatigue. The unit shall include provisions for purging air from the fuel system should fuel starvation occur during operation, or following fuel system maintenance. A readily accessible manual fuel tank shutoff valve shall be provided to prevent continuous fuel spillage when fuel lines are disconnected. Fuel tank shall be vented to prevent collapsing of the tank and fuel starvation to engine. The tank shall be designed so that the compressor can be operated on a 15 degree slope in any direction. A drain valve shall be provided for emptying fuel and sediment into a container outside the compressor unit without removal of the tank or any other major component.

3.10.7 Engine diagnostic and emergency shutdown systems.

3.10.7.1 Engine diagnostic system. If the engine is equipped with an electronic control module, a diagnostic system shall be provided with a means to indicate engine faults; it shall be equipped with a Control Area Network CAN buss connector. If the compressor unit is equipped with a diagnostic or built-in-test system, the engine diagnostic system shall be integrated with it; if not, it shall be a stand alone system.

3.10.7.2 Engine emergency shutdown system. The engine shall be equipped with an engine emergency shutdown system consisting of a fuel cutoff solenoid activated by the following conditions:

a. Low oil pressure, less than 10 psi or in accordance with the engine manufacturer’s recommendations.

b. Coolant over heat or cylinder head temperature over heat condition in accordance with the engine manufacturer’s recommendations.

c. Engine over speed should the engine exceed 110% rated speed. This is required for engines over 100 bhp and optional for engines less than 100 bhp rated horsepower.

3.10.8 Engine operator instruments. The following instruments shall be provided to the engine operator:

a. Tachometer.

b. Coolant temperature gauge.

c. Low coolant level indicator.

d. Oil pressure gauge.

e. Oil temperature gauge.

f. Fuel level gauge.

g. Hour meter.

3.11 Electrical system. The compressor unit shall have a 12‑volt, negative ground electrical system in accordance with 3.13.1.2 of SAE ARP1247 except as otherwise specified herein.

3.11.1 Alternator. A single or dual alternator charging system in accordance with 3.13.1.4.9 of SAE ARP1247 shall be provided. The alternator shall be capable of restoring the energy expended during an engine start in less then 15 minutes of engine idle at -40º F.

3.11.2 Batteries and battery compartment.

3.11.2.1 Batteries. Batteries shall be of the commercial maintenance-free sealed lead acid, starved electrolyte, gas recombination, spiral wrapped, absorbent gas mat (AGM), top post type in accordance with MIL‑B‑18013/1.

3.11.2.2 Battery compartment. The batteries shall be enclosed in a corrosion-resistant, weatherproof box or compartment and shall be readily accessible.

3.11.2.3 Battery cables. The battery cables shall be sized to handle the system voltage and current levels, be clearly identified with "+" and "-" or red and black markings, and shall not be spliced.

3.11.3 Winterization system. The enclosure of the compressor unit shall be designed for connection to a military designed heater (e.g., H-1 or New Generation Heater). Provisions shall be included for the attachment of one 12-inch diameter duct connection. Duct connection and cover shall be in accordance with SAE AS7365. The coupling at the compressor unit shall be a male coupling in accordance with Drawing 50C24033. Dust cover shall be securely fastened to the enclosure by a chain or other means to prevent loss. If necessary, heater ducting shall be provided within the compressor unit enclosure to direct the heated air onto all critical moving parts that may be restricted due to congealed oil or ice. Duct attachment shall not project beyond the enclosure of the compressor unit.

3.12 Workmanship. The compressor unit, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.12.1 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.12.2 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.12.3 Gear and lever assemblies. Gear and lever assemblies shall be properly aligned and meshed and shall be operable without interference, tight spots, loose spots, or other irregularities. Where required for accurate adjustment, gear assemblies shall be free of excessive backlash.

3.12.4 Cleaning. The compressor unit shall be thoroughly cleaned. Loose, spattered, or excess solder; welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. Pre-production inspection (see 4.2).

b. Operational inspection (see 4.3).

c. Conformance inspection (see 4.4.).

4.2 Pre-production inspection. The pre-production compressor units shall be subjected to the demonstrations, examinations, tests, and analyses described in 4.6.1 through 4.6.14. The contractor shall provide or arrange for all test equipment and facilities.

4.3 Operational inspection. All operational inspection shall be satisfactorily completed and approved prior to final pre-production acceptance.

4.4 Conformance inspection. Each pre-production compressor unit shall be subjected to the examinations and tests described in 4.6.1.

TABLE II. Requirement verification matrix.

4.6.7.1 Weight and center of gravity test.

4.6.7.2 Dimension measurement.

4.6.8.3 Equipment removal and reconfiguration demonstration.

4.6.9.1 Preventive maintenance demonstration.

4.6.6.2 Low temperature storage and operation test.

4.6.6.2 Low temperature storage and operation test.

3.10.6.1 Engine operating fuels.

4.6.6.2 Low temperature storage and operation test.