PD12WRGRVEA10_-19_Feb_2013.pdf

PD12WRGRVEA10

AMSC N/A FSC 4320

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

INCH-POUND

REVISION A

CAGE 98752

19 February 2013

PURCHASE DESCRIPTION

HPU, HYDRAULIC, DIESEL/ELECTRIC

1. SCOPE

This Purchase Description (PD) covers the requirements for a four wheeled, trailer mounted, diesel and electric driven, cold weather operable, hydraulic pumping unit (HPU) capable of operating multiple aircraft jacks simultaneously and uniformly during military aircraft jacking operations. Both diesel and electric prime movers are to be integrated within a single HPU. The HPU shall be air transportable on C-17, C-130, and C-5 aircraft.

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 document to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C/26173 Gray

COMMERCIAL ITEM DESCRIPTIONS

A-A-52464 Coupler, Drawbar, Ring: Light Duty, 60,000 Lb GVW;

Offset (Taper Shank), 60,000 Lb GVW; And Heavy Duty, 120,000 Lb GVW

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5624U(1) Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-B-18013/1 Battery, Storage, Support Equipment MIL-PRF-23377J(2) Primer Coatings: Epoxy, High-Solids MIL-DTL-25959F Tie Down, Tensioners, Cargo, Aircraft MIL-PRF-26915D(2) Primer Coating, for Steel Surfaces MIL-PRF-27260C Tie Down, Cargo, Aircraft, CGU-1/B MIL-DTL-53030C Primer Coating, Epoxy, Water Reducible, Lead and

Chromate Free MIL-DTL-81706B(1) Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys MIL-DTL-83133G Turbine Fuels, Aviation, Kerosene Type, JP-8 (NATO

F-34), NATO F-35, and JP-8+100 (NATO F-37) MIL-PRF-83282D(1) Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon

Base, Metric, NATO Code Number H-537

MIL-PRF-5606

Hydraulic Fluid, Petroleum Base, Aircraft, Missile, Ordnance

MIL-PRF-87257

Hydraulic Fluid, Fire Resistant; Low Temperature, Synthetic Hydrocarbon Base, Aircraft and Missile

MIL-PRF-85285D(3) Coating: Polyurethane, Aircraft and Support Equipment

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N Identification Marking of U.S. Military Property MIL-STD-209K Lifting and Tiedown Provisions MIL-STD-461F Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment MIL-STD-810G Environmental Engineering Considerations and

Laboratory Tests MIL-STD-882E Standard Practice for System Safety MIL-STD-889B(3) Dissimilar Metals MIL-STD-1366E Interface Standard for Transportability Criteria MIL-STD-1472F(1) Human Engineering

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-470A Designing and Developing Maintainable Products and Systems

MIL-HDBK-781A Handbook for Reliability Test Methods, Plans, and Environments for Engineering, Development, Qualification, and Production

MIL-HDBK-1791(2) Designing for Internal Aerial Delivery in Fixed Wing Aircraft

MIL-HDBK-1791 C-17

Appendix

Designing for Internal Aerial Delivery in Fixed Wing Aircraft C-17 Appendix

(Copies of these documents, except for MIL-HDBK-1791 C-17 Appendix and GOST 10227-86, 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. A copy of GOST 10227-86 can be obtained from the PCO.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications of the exact revision level shown form a part of this document to the extent specified herein.

AIR FORCE DRAWING

50C24033 Coupling – Male, 12 Inch Air Duct

(Copy of this drawing may be obtained can be obtained from the Procuring Contracting Officer

(PCO))

AIR FORCE INSTRUCTION (AFI)

AFI 32-7086 Hazardous Materials Management, dated 1 November

(Copies of this document are available online at http://www.e-publishing.af.mil/.)

2.3 Non-Government publications. The following documents 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.

ASME INTERNATIONAL

ASME B40.1 Gauges - Pressure Indicating Dial Type - Elastic Element

(Application for copies should be addressed to ASME International Three Park Avenue, New York, NY 10016-5990)

ASTM INTERNATIONAL (ASTM)

ASTM D975 Standard Specification for Diesel Fuel Oil ASTM D1655-05 Standard Specification for Aviation Turbine Fuels

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken PA 19428-2959.)

AMERICAN WELDING SOCIETY (AWS)

http://assist.daps.dla.mil/quicksearch/ http://www.e-publishing.af.mil/

D1.1/D1.1M:2006 Structural Welding Code–Steel–20th Edition D1.2/D1.2M:2003 Structural Welding Code–Aluminum–Fourth Edition

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

WD 6 2002 Wiring Devices-Dimensional Specifications

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

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 National Electrical Code

(Application for copies should be addressed to National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

ARP1247D General Requirements for Aerospace Ground Support Equipment, Motorized and Nonmotorized

AS8090 Mobility, Towed Aerospace Ground Equipment, General Specification For

SAE J 517 Hydraulic Hose

SAE ARP1801

Exterior Sound Level of Specialized Aircraft Ground Support Equipment, Measurement of

SAE J447 Prevention of Corrosion of Motor Vehicle Body and Chassis Components.

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

TIRE AND RIM ASSOCIATION

“2012 Year Book”

(Application for copies should be addressed to The Tire and Rim Association, Inc., 175 Montrose West Ave., Suite 150, Copley OH 44321.)

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, http://www.nema.org/ however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Preproduction inspection. When specified (see 6.2), one sample shall be subjected to preproduction inspection in accordance with 4.2.

3.2 HPU description. The HPU is a trailer mounted diesel and electric driven unit capable of operating multiple aircraft jacks simultaneously and uniformly during military aircraft jacking operations. Both diesel and electric prime movers are integrated within a single HPU. The HPU shall be air transportable on C-17, C-130 and C-5 aircraft.

3.2.1 Dual prime movers. The HPU shall have dual power capability consisting of a diesel engine and an electric motor.

3.2.2 Dual pumps. The diesel engine and electric motor shall each drive independent hydraulic pumps. The pumps shall work in a common hydraulic system.

3.2.2.1 Flow and pressure. The HPU pumps shall each provide 4 gallons per minute total flow at 4,000 pounds per square inch (psi) - At any given time, only one pump is operating.

3.2.3 Power mode selection. Diesel or electric power mode selection shall be handled automatically with absolute minimum additional controls requiring operator intervention at the control panel.

3.2.4 Operating positions The HPU shall be capable of functioning satisfactorily when its normal operating plane is at an angle of 8-1/2 degrees (°) in any direction from horizontal.

3.3 Design and construction. Design and construction of the HPU shall be in accordance with requirements of SAE ARP 1247 and SAE AS8090 for Type II, Group C mobility except as otherwise specified herein. The HPU shall be designed as a self-contained, mobile hydraulic power unit with cold weather operability while providing not less than 4 gallons per minute (gpm) total flow at 4,000 psi gage continuously from three hose reels. The HPU shall be designed for use in aircraft hangars where such hangar space from floor level to a height 18 inches above floor level is a Class I, Division II hazardous area. Design and construction for use in these areas shall conform to NFPA 70 Articles 500, 513 and others as applicable.

Components of the HPU shall be arranged for maximum ease of operation and maintenance consistent with the functional requirements specified herein. The HPU shall be designed for continuous-duty operation from sea-level up to and including 7,000 feet (ft) altitude. The HPU shall be built to withstand the strains, jars, vibrations, accelerations and other conditions incident to air transport, ground shipping, towing, storage, installation, and service. It shall be designed and constructed so that no parts will work loose under any condition of service. The construction shall be such as to prevent conditions hazardous to personnel or detrimental to equipment. The service life of the unit with regular maintenance shall be approximately 20 years. The HPU shall be designed and constructed in accordance with all applicable European

Union (EU) requirements in order to have the “CE” marking affixed (see 3.3.3.1). All components used in the HPU must be evaluated and rated by the manufacturer of the component for satisfactory cold weather operability and reliability at -25°F.

3.3.1 Materials, protective coatings, and finish.

3.3.1.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should 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.

3.3.1.2 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the HPU 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 HPU shall also be primed and painted.

3.3.1.2.1 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, chemical conversion coating applied in accordance with the manufacturer’s directions prior to priming.

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

3.3.1.2.2.1 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-53030 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.

3.3.1.2.2.2 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.

3.3.1.2.3 Topcoat. Topcoat shall be polyurethane in accordance with Type I, 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.

3.3.1.3 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 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.

3.3.1.4 Finish. The exterior finish color of the HPU shall be GRAY, Color Number 26173 of

FED-STD-595.

3.3.1.5 Exclusion of water. The design of the HPU shall be such as to prevent water leaking into, or being driven into, any part of the HPU interior when either in an operating or travelling configuration. All doors, panels, covers, etc., shall be provided with sealing arrangements such that the entry of water is minimized when these items are correctly closed. Particular care shall be taken to prevent wetting of equipment and heat and sound proofing materials. Sharp corners and recesses shall be avoided so that moisture and solid matter cannot accumulate to initiate localized attack. Sealed floors with suitable drainage shall be provided for storage compartments, engine compartments, and other areas in the HPU that could collect and retain water.

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

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

3.3.1.5.3 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 10° incline in any plane. The minimum size of the drain holes shall be 0.25 inch.

3.3.2 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 centers of gravity of the HPU shall be stenciled on the unit within 1.0 inch of the calculated centers of gravity. The center of gravity shall be identified with a full hydraulic reservoir as well as an empty hydraulic reservoir.

3.3.3 Identification and information plates.

3.3.3.1 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the HPU in a readily accessible location. The identification plate shall contain the following information: Nomenclature, part number, serial number, date of manufacture, contract number, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). The HPU 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. The “CE” marking shall be affixed in accordance with EU requirements on or adjacent to the identification plate.

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

a. Side and rear silhouette views of the HPU.

b. Horizontal and vertical location of the center of gravity of the HPU 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.

3.3.4 Safety.

3.3.4.1 Environment, Safety, and Occupational Health (ESOH).

3.3.4.1.1 System safety. The contractor is responsible for overall safety as it relates to the design of the HPU. The design of the HPU shall not contain any system safety mishap risk categories greater than medium as defined in Table A-IV of MIL-STD-882.

3.3.4.1.2 Hazardous material. The design shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials and the generation of toxic or noxious gases. The HPU shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. The HPU shall not contain or use hexavalent chromium.

For the purposes of this requirement, the Class I ODS and controlled substances identified in Chapter 4 of AFI 32 7086 shall not be used in any system, component, or process.

3.3.4.2 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.

All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located so as to provide adequate clearance from moving parts and high operational temperatures. Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

3.3.4.3 Foreign object damage (FOD). All loose metal parts, such as pins or connector covers, shall be securely attached to the HPU 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.

3.3.4.4 Sound levels. The maximum operational sound level produced shall not exceed 84 decibels (dBa) when tested in accordance with SAE ARP1801.

3.3.5 Electromagnetic interference (EMI). The HPU shall be in accordance with the following radiated emission and susceptibility requirements of MIL-STD-461: RE102 and RS103.

3.3.6 Human engineering. Concepts of human engineering and ergonomics shall be applied in the design of the HPU. Attention shall be focused on the entire system to insure safe aircraft jacking operations. The operator panel and controls layout shall be designed for simplicity, ease of use, clarity of labels and an unobstructed view of the aircraft on jacks. All system operations, service and maintenance functions shall be configured to be accomplished by a wide range of personnel from 5th percentile female to 95th percentile male. The HPU shall be constructed such that adjustments, repairs, and overhaul can be easily accomplished by the personnel of operating units and overhaul bases using common hand tools. The HPU shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance.

3.3.7 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 threads shall have a minimum thread engagement in accordance with Table I.

TABLE I. Minimum thread engagement.

Material Minimum Thread Engagement Steel 1.0 times the nominal fastener diameter

Cast iron, brass, or bronze 1.5 times the nominal fastener diameter

Material Minimum Thread Engagement Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.3.8 Welders and welding. All welders shall be certified to weld in accordance with AWS D1.1 and AWS D1.2, as applicable. Upon request, the contractor shall make available to the Government certifications for all welders being utilized on the HPU. Welding procedures and all welding on the HPU shall be in accordance with AWS D1.1 and AWS D1.2, as applicable. 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.

3.3.9 Service life. The HPU shall be designed for a minimum service life of 20 years.

3.4 Environmental conditions.

3.4.1 Operating temperature range. The HPU shall be capable of operating in ambient temperatures ranging from -25°F to 130°F. The winterization system, 3.10.11, may be used as a starting aid in accordance with 3.10.2.5.

3.4.2 Storage temperature range. The HPU shall be capable of being stored in ambient temperatures ranging from -65°F to 160°F.

3.4.3 Precipitation.

3.4.3.1 Rain. The HPU shall be capable of storage and operation during rainfall of 4 inches per hour for two consecutive hours with winds of up to 40 MPH at angles from vertical to 45°.

3.4.4 Solar radiation. The HPU 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 HPU 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 HPU shall be suitable for operation and storage in conditions encountered in a tropical environment.

3.4.6 Salt fog. The HPU 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 HPU shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance.

3.5 Weight and dimensions. Overall weight and dimensions shall not exceed:

Weight 3,100 pounds MAX (wet weight including 56 gallons hydraulic fluid) Length 90 inches MAX Width 60 inches MAX Height 51 inches MAX

3.6 Transportability.

3.6.1 Surface transportability. The HPU 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.

3.6.2 Air transportability. The HPU shall be transportable on C-130, C-5, and C-17 aircraft.

Design criteria can be found in MIL-HDBK-1791. In all air transport configurations, the HPU 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 HPU 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 HPU shall roll on and off the aircraft, negotiating the required maximum ramp angles without shoring.

3.6.2.1 Shoring. The HPU shall be air transportable without shoring.

3.6.2.2 Axle weight. Individual axle weight shall not exceed 1800 pounds.

3.6.2.3 Tire pressure. Tire pressure shall not exceed 100 pounds per square inch (psi) and shall not be reduced for air transport.

3.6.2.4 Winch points. Winch points shall be provided at the front and rear of the HPU for aircraft loading using the aircraft’s winch. Tie down rings at the front of the unit may be used for this purpose.

3.6.2.5 Equipment removal and reconfiguration. There shall be no special preparation, equipment removal, or re-configuration required for air transport other than draining of hydraulic fluid.

3.6.3 Lifting and tiedown provisions.

3.6.3.1 Crane Lifting provisions. Four of the tie down provisions of 3.6.3.3 shall serve double duty as crane lifting provisions. Each of these points shall be marked "Lift Point". The lifting provisions shall be in accordance with 5.1 through 5.1.4 of MIL-STD-209.

3.6.3.2 Fork lifting provisions. The HPU shall include two transverse mounted tubes, each capable of accommodating an 8 inch wide by 2 3/4 inch thick fork. The tubes shall be placed an adequate distance apart to insure stable and safe fork lifting capability. The HPU center of gravity, with and without fluid in the hydraulic tank shall fall within the inside dimension between the tubes.

3.6.3.3 Tie down provisions. The HPU shall be equipped with eight tie down fittings. Fittings shall be paired on each of the sides, front, and back of the trailer. The HPU shall be symmetrically restrained during air and ground transport. Tie down points shall be suitably rated for air transport of the HPU and 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 HPU. The tie down provisions shall be in accordance with 4.1 through 4.12 of MIL-STD-209.

3.7 Inspection and servicing provisions.

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

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

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

3.7.1 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.

3.7.2 Error-proof design. The design of the HPU 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 designed 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.

3.7.3 Special tools. The HPU shall be designed such that no special tools are required (see 6.3.2).

3.8 Mobility. The HPU shall be trailer mounted in accordance with SAE AS8090 for Type II, Group C mobility except as otherwise specified herein. The rectangular outline of the tires and wheels (top view) shall not extend beyond the rectangular outline of the deck of the HPU. The requirements for reflectors and safety chains in paragraphs 3.14.1 and 3.15 of SAE 8090 are not included.

3.8.1 Terrain.

3.8.1.1 Paved surfaces. The HPU shall be towable at speeds up to 20.0 miles per hour (mph) over paved surfaces.

3.8.1.2 Graded gravel. The HPU shall be towable at speeds up to 10.0 mph over graded gravel.

3.8.1.3 Belgian block. The HPU shall be towable at speeds up to 8.0 mph over Belgian block.

3.8.2 Towing force. The towing force shall be in accordance with 3.3.4 of SAE AS8090.

3.8.3 Clearances. Ground clearance, ramp breakover angle, and angles of approach and departure shall be in accordance with 3.3.9 of SAE AS8090.

3.8.4 Suspension. The HPU shall have a suspension system in accordance with 3.4.1.2 of SAE AS8090. Shock absorbers are not mandatory.

3.8.5 Steering. The HPU shall have a steering system in accordance with 3.5.1.1 of SAE

AS8090.

3.8.6 Parking brakes. The HPU shall have parking brakes in accordance with 3.6.1 of SAE

AS8090.

3.8.7 Bumper. The HPU shall have a rear bumper in accordance with 3.7 of SAE AS8090. The design strength of the rear bumper with 3X design safety factor shall be sufficient to support the full rated horizontal and vertical capacity of the pintle hook.

3.8.8 Pintle hook. The HPU shall have a rear pintle hook in accordance with 3.13 of SAE AS8090. The PH15 commercial pintle hook rated at 15 Ton capacity is acceptable in lieu of MS51335 identified in SAE AS8090.

3.8.9 Towbar. The HPU shall be equipped with a towbar in accordance with 3.17.1 of SAE AS8090. It shall have a lunette eye in accordance with A-A-52464 and accommodate any pintle hook height from 22 through 30 inches. When in operation or storage (that is, not being towed), the towbar shall be stowed upright, secured, and not hinder visibility, operation, or maintenance.

3.8.10 Tires and wheels. The HPU shall be equipped with single or dual tubeless steel belted radial tires with on/off-road type tread mounted on steel disc wheel assemblies. Tire and wheel assemblies shall be identical at all wheel positions. Tires and wheels shall be in accordance with the Tire and Rim Association “2012 Year Book” requirements for this application.

3.9 Housing. The HPU components and control panel shall be completely enclosed and protected by a weather-resistant housing. The enclosure, covers, doors, etc., shall be sufficiently sealed as to be tolerant of heavy rain, blowing dust and sand. It shall be weatherproof and designed to prevent the intrusion of water, sand, and dust into critical operating components. To provide air flow while protecting internal components during storage or foul weather, louvered panels or doors shall be provided. In particular cases, hinged, sliding, or rotating closures or covers may be used to provide closure and appropriate seal of entry points. Any such closures shall be easy to operate and readily accessible. Provisions shall be incorporated to secure the doors and closures rigidly in the full-open or full-closed position. The housing shall be capable of supporting a 200-pound (lb) weight distributed evenly over a 4-1/2 by 5 inch area and applied in any location on the top of the HPU. The housing shall be braced to prevent distortion or excessive vibration during handling and operation of the HPU, or handling of the housing while removed from the HPU. The HPU shall be designed so that water or hydraulic fluid spilled any place within the housing will drain to the exterior. The housing shall be easily removable by disconnecting fasteners and lifting or sliding the entire housing off the remainder of the HPU.

3.9.1 Compartment. A handbook compartment 2 by 9 by 12 inches, or larger, shall be provided and permanently attached within the housing.

3.9.2 Operator control panel. A control panel shall be provided for mounting all meters, valves, indicators, gages, switches, and controls furnished with the HPU. The control panel shall be supported by a self-supporting framework. The control panel frame shall be bolted or welded to the trailer bed and positioned so that the wheels, tow bars, et cetera, will not interfere with the operator. The control panel shall be located at sufficient height above the ground and inclined at a sufficient angle (10° minimum) to facilitate observation and operation of all items by an operator approximately 5 ft 4 inches tall standing erect on the ground. Instruments subject to errors from vibration shall be shock mounted. Identification and marking of controls shall be in accordance with 3.13.9 of SAE ARP 1247.

3.10 Engine and related equipment. The HPU shall incorporate a multi-fuel liquid cooled diesel engine (including forced air/oil cooled engines) of appropriate power rating to meet all of the requirements of this specification at 7,000 feet elevation. 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 horsepower requirement. The required engine horsepower shall be determined by detailed analysis in accordance with 3.13.1.4.1 of SAE ARP1247, (SAE ARP1052), demonstrating that the engine has been properly selected to provide adequate horsepower when derated for the worst case fuel, environmental, and performance conditions specified herein.

3.10.2 Engine starting system.

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

3.10.2.2 Starter switch. A waterproof starter button shall be incorporated on the control panel to start the diesel engine.

3.10.2.3 Selector valve interlock. A selector valve interlock shall enable diesel engine starting only when the selector valve is in the hold position.

3.10.2.4 Master switch. A waterproof master switch shall be incorporated on the control panel to enable the diesel engine support electronics, gages, starting motor circuit and fuel delivery for the diesel engine. This switch must be activated to allow starting of the diesel engine. When the master switch is “on” the electronics supporting the electric motor driven pump are disabled.

3.10.2.5 Engine starting aids. The engine shall start within 15 seconds cranking in any ambient temperature within the required operating range of the HPU. Internal engine starting aids and heat from the winterization system 3.10.11 may be used prior to and during the start period to facilitate engine starting under the following conditions:

TABLE II. Engine starting aids.

Temperature Range Starting Aids Permitted

40° F through 130°F None

0° F through 39° F Internal engine starting aids

-25 F through -1° F Internal engine starting aids and heat from the winterization system

3.10.3 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 HPU 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.

3.10.4 Engine cooling system. The engine cooling system for conventional liquid cooled engines (with radiator) 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 -25F. The engine out (top of radiator) coolant temperature shall not exceed 210° F or the engine manufacturer’s recommendations while operating continuously within the range -25°F to 130°F, (see 3.4.1).

3.10.5 Engine lubrication system. The engine lubrication system shall be designed so that the HPU can be operated on a 8 1/2° incline in any plane.

3.10.5.1 Engine oil. The engine shall be compatible with Grade 15W40 of MIL-PRF-2104 from 0° F to 130°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 -25° F to 60° F.

3.10.5.1.1 Engine oil operating temperature. The engine oil sump temperature shall not exceed 250°F or the engine manufacturer’s recommendations while operating continuously within the range -25°F to 130°F, (see 3.4.1).

3.10.5.1.2 Engine oil consumption. The engine oil consumption shall meet or exceed the engine manufacturers’ specifications.

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

ARP1247.

3.10.6 Exhaust and muffler system. The exhaust and muffler system design shall conform to engine manufacturer’s requirements. The muffler pipe, muffler, clamps and brackets shall be of stainless steel construction. The exhaust shall be routed such that components of the HPU are not damaged by heat from the exhaust. Engine exhaust shall discharge vertically, such that exhaust gasses are not drawn into the engine air intake or engine cooling system. The exhaust outlet shall be protected from the environmental extremes and water intrusion from cleaning equipment or pressure washing. Exposed sections of the exhaust shall be shielded to avoid inadvertent personnel contact with hot exhaust components. The exhaust shall be designed for use in aircraft hangars where such hangar space is a Class I, Division II, hazardous area. Design and construction for use in these areas shall conform to NFPA 70 Articles 500, 513 and others as applicable. Components of the exhaust shall not be less than 18 inches above floor. Sound level control provided by the system shall be consistent with the overall unit sound level requirements stated in 3.3.4.4. The exhaust system outlet shall be directed vertically through the top of the housing as far as possible from the operator and directed away from personnel accessing any control panel or equipment compartment and the engine air intake, and shall not be directed toward the ground.

3.10.7 Engine fuels and fuel system.

3.10.7.1 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 -25°F to 130°F ambient air temperature.

d. JP-8, in accordance with MIL-DTL-83133 -25°F to 130°F ambient air temperature.

3.10.7.2 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 3.10.7.1. 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.

3.10.7.2.1 Fuel pump. The fuel pump shall be in accordance the engine manufacturer specifications. The fuel pump shall be capable of rapidly re-priming the engine fuel system following fuel exhaustion.

3.10.7.2.2 Fuel filter. The fuel filter system shall provide clean fuel to the engine and remove any water contamination. The fuel filter shall be in accordance the engine manufacturer specifications. The fuel filter shall be readily accessible to an operator or mechanic. A combination fuel filter and fuel/water separator may be provided in lieu of separate components.

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.

3.10.7.2.3 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 HPU can be operated on a 8-1/2° 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 HPU without removal of the tank or any other major component. The fuel tank shall have a fuel fill opening of not less than two inch inside diameter and shall be designed to drain fuel spillage overboard for collection outside the HPU. The filler opening shall be provided with a screen for removing impurities. 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. The fuel tank shall be of adequate capacity to provide fuel for at least 4 hours of full-load operation shall be provided and mounted within the outline of the HPU housing. The fuel tank shall be of stainless steel construction.

3.10.8 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. Engine temperature over heat condition in accordance with the engine manufacturer’s recommendations.

Note: A check engine light or separate indicator lights on the control panel shall illuminate under the above fault conditions.

3.10.9 Engine instrumentation and controls. The following instrumentation shall be provided on the HPU control panel. All engine instruments and controls shall be grouped together on the control panel.

A Manual throttle control of engine speed

a. Tachometer.

b. Engine temperature gauge.

c. Check engine light or separate lights indicating low oil pressure or high engine temperature shut down.

d. Engine oil pressure gauge.

e. Ammeter

f. Alternator warning light

g. Fuel level gauge.

h. Hour meter.

3.10.9.1 Engine speed governor. The engine speed set by the throttle shall be maintained constant within 5% of set speed under varying load by a mechanical governor or other appropriate electronic closed loop control.

3.10.10 Diesel engine electrical system. The HPU shall have a 12 volt, negative ground electrical system in accordance with 3.13.1.2 of SAE ARP1247 except as otherwise specified herein.

3.10.10.1 Emergency stop button. An emergency stop button shall immediately stop the diesel engine or electric motor and completely disable all supporting electronics for either prime mover without the use of any other control. The emergency stop button shall be labeled and encircled by a one inch wide red band.

3.10.10.2 Alternator. A single 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 -25 F.

3.10.10.3 Battery and battery compartment.

3.10.10.3.1 Battery. The battery 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.

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

3.10.10.3.3 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.

3.10.11 Winterization system. An auxiliary heater connection shall be located on the side of the HPU for use in cold weather. The heater connection shall be in accordance with Drawing 50C24033 or equivalent and shall be easily accessible for connecting a ground heater. A protective cover shall be provided to prevent the entrance of foreign material through the heater connection when the heater is disconnected. Heat ducts, deflectors, insulation, and enclosures shall be provided, as required, to direct heated air to sections of the engine, battery, etc., as necessary to provide an auxiliary warm-up assist capability.

3.11 Electric motor and related equipment. In addition to the diesel engine and associated hydraulic pump, the HPU shall contain a second hydraulic pump driven by an electric motor.

The electrical system for the electric motor shall be water tight and shall comply with NFPA 70.

3.11.1. Electric power requirement. The HPU shall meet all of the performance requirements of this specification when operating from an electric motor powered by 380/460 Volt, 50/60 Hertz, 3 Phase power.

3.11.1.1 Electric motor horsepower requirement. The required electric motor horsepower shall be determined by detailed analysis demonstrating that the motor has been properly selected to provide adequate horsepower when derated for the worst case electrical power, environmental, and performance conditions specified herein.

3.11.2 Selector valve interlock. A selector valve interlock shall enable electric motor starting only when the selector valve is in the hold position.

3.11.3 Automatic motor protection. The electric motor shall be configured for appropriate thermal and overload protection. Automatic shutdown of the HPU shall be incorporated for thermal or mechanical overload of the motor.

3.11.4 Electric motor start and stop switches. Electric motor start and stop switches shall be incorporated on the control panel. The start and stop switches shall be clearly marked “Electric Pump Motor Start”, “Electric Pump Motor Stop”. A run indicator light shall be incorporated near the start switch. The indicator light shall illuminate when the electric motor is running. The indicator light shall be clearly marked ”Pump Running When Illuminated”. Whenever the diesel engine is running, (master switch is on) the electric motor starting circuits are disabled.

3.11.5 Power cord. The HPU shall be equipped with a power cord with a minimum length of 40 feet and with a 460V, 3 phase plug in accordance with MS27265. Applicable requirements of NFPA 70 for use in Class I, Division II, hazardous area shall be met. The cord shall be stowed in a designated compartment within the enclosure.

3.11.6 Utility power disconnect. A utility power disconnect switch shall be provided on the HPU. When the HPU is connected to utility power and the utility power disconnect is switched to “on” the diesel engine electronics are disabled and the diesel engine shall not start. Whenever the diesel engine is enabled to start or is running, (master switch is on) the electric motor starting circuits are disabled.

3.12 Hydraulic system. The hydraulic system shall be in accordance with 3.13.1.3 of SAE ARP1247 except as otherwise specified herein. O-ring face seal hydraulic fittings may be used in lieu of flared fittings (see 3.13.1.3.12 of SAE ARP1247). All hydraulic system components, including the hydraulic tank, shall comply with all corrosion resistance requirements specified herein. Elements of the hydraulic system such as the selector valve, manual flow control valves, suction relief valve, adjustable high pressure relief valve, safety relief valve, etc., shall be integrated into a manifold block assembly to simplify the hydraulic system.

3.12.1 Hydraulic fluids. The hydraulic system shall be compatible with hydraulic fluids in accordance with MIL-PRF-87257, MIL-PRF-83282, MIL-PRF-5606.

3.12.2 Hydraulic pumps. The hydraulic pumps shall be of adequate rating to meet the requirements specified herein, (see 3.2.2.1).

3.12.3 Pump case drain. A pump case drain shall be provided in accordance with the pump manufacturer’s recommendations.

3.12.4 Pressure check valve. A pressure check valve shall be provided to prevent reverse flow through the pump.

3.12.5 Gages.

3.12.5.1 High pressure gage. A high quality, flush-mounted, corrosion resistant, high-pressure gage with 4-1/2 inch diameter or larger diameter dial shall be provided. The high-pressure gage shall provide a range from 0 to 5,000 psig and accuracy to within 1 percent or less full-scale range. The gage shall conform to ASME B40.1.

3.12.5.2 Gage connections. Gages shall be connected to the panel with flexible hose of sufficient length to permit removal and installation from the front of the panel.

3.12.5.3 Gage lines. The high pressure gage line shall be provided with a needle shutoff valve, a pressure surge suppression device, and gage test fitting. The vacuum gage line shall be provided with a needle shutoff valve and a gage test fitting.

3.12.5.4 Gage shutoff valves. The needle shutoff valves shall be of the panel-mounted type with a corrosion-resistant stem. The valves shall be suitable for working pressures up to 5,000 psi.

3.12.5.5 Gage test fittings. The gage test fittings shall be…