Revised_Commercial_Item_Description.doc

COMMERCIAL ITEM DESCRIPTION

FOR ENGINE AND TRANSMISSION DYNAMOMETERS

Attachment B

Requirements

1.1. Dynamometers. The dynamometers shall load test engines, cross drive transmissions, and inline transmissions. All engines and transmissions listed in Table I shall be tested. The engines in Table I shall be tested by the engine dynamometer (see section 1.2) and the transmissions in Table I shall be tested by the transmission dynamometer (see section 1.3) Table I Units Under Test (UUT) List

D0030-4 D1158

GM 6.2 L

NSN 2815-01-314-7940

GM 6.5L

NSN 2815-01-461-7078

GM 6.5L Turbo

NSN 2815-01-439-8164

GM 4L80E

PN 12339146

NSN 2520-01-161-2136

PN 24202329

NSN 2520-01-489-0849

NSN 2520-01-489-0850

D0198 D1062 D1063 D1073

CAT C12

NSN 2815-01-522-2895

PN 3537437

NSN 2815-01-474-5704

Allison HD4070

PN 3000002

NSN 2520-01-479-2170

NSN 2520-01-474-5771 W/ CON

Allison 4700SP

PN 3564554

NSN 2520-01-536-4208

Logistics Vehicle System Replacement

(LVS-R)

D0886 D0887 D1214

NSN 2520-01-566-8362

NSN 2520-01-579-3296 W/ CON

D0027

CAT C7

NSN 2815-01-558-2184

Allison 3500SP

PN E014761

NSN 2520-01-547-4017

ASET 400 AI

PN 11GB22738Y

NSN 2815-01-537-2689

Allison HD4500RDS

NSN 2520-01-537-2693

PN 3818307

NSN 2520-01-576-4518

E0856 (R-7) E0796 (C-7) Cummins

VTA903T525

PN 7010027

NSN 2815-01-463-8066

TWIN DISC HS525

PN 7010146

NSN 2520-01-472-3051

NSN: 2520-01-472-6681 W/ CON

6V53 PN 96010A0018

A1: NSN 2815-01-442-7645

A2: NSN 2815-01-550-2608

Cummins

ISB 6.7L

Allison 653

NSN 2520-21-906-4746

Allison 2500SP

NSN 2815-01-505-1476

Allison MD 3070PT

NSN 2520-01-493-6059

30 KW Tactical Quiet Generator

MEP-805 A/B, 60 HZ

B0953

B0971A

B0971B

B0971C

MEP805A

Deere 4039TF002

NSN 2815-01-350-2208

MEP805B

Deere 4045TF151

NSN 2815-01-462-2289

Not Applicable

60 KW Tactical Quiet Generator

MEP-806 A/B, 60 HZ

B1016A

B1016B

B1016C

B1021A

B1021B

B1021C

MEP806A

Deere 6059TF002

NSN 2815-01-350-2209

MEP806B

Deere 6068TF151

NSN 2815-01-462-3596

Not Applicable

100 KW Tactical Quiet Generator

MEP-807 A,B,C, 60 HZ

NSN 2815-01-040-3662

Not Applicable

PN: RE537203,

NSN 2815-01-570-0260

Not Applicable

Perkins 704-30T Model TX51-19MD:

Deutz BFM 2011 Not Applicable

Tractor, Rubber Tired, Articulated Steering, Multi-Purpose (TRAM)

John Deere 624KR

PN RE534832,

NSN 2815-01-266-0376

Not Applicable

QSC 8.3

Allison 3500SP

1.2. Engine dynamometer. The engine dynamometer shall be a water brake dynamometer that tests all items listed in the “Engine” column in Table I.

1.2.1. Power capacity. The engine dynamometer shall exhibit a capacity no less than 700 HP. The torque tested by the dynamometer shall be 2500 foot-pounds and below. The dynamometer shall provide the capability to test 4000 RPM and below.

1.2.2. Tested parameters. At a minimum, the parameters measured by the tester and printed on the engine dynamometer’s output report shall include; RPM, torque, power, oil pressure, oil temperature, and coolant temperature.

1.2.3. Electronic control. The engine dynamometer shall have an electronic control interface located on a control station in the control room, see section 1.2.14 for more detail. This interface shall display measured parameters in real time.

1.2.4. Adaptors. All adaptors including connectors, cables, plugs, mounting hardware, plates, covers, mounting brackets, lifting brackets, drive shafts, linkages, actuators, fittings, hoses, and other components necessary to properly control, connect, and test all engines in Table I shall be included with the engine dynamometer. All items provided with the engine dynamometer shall be stored in one or more cabinets specific to the engine dynamometer.

1.2.5. Engine starting. The engine, when mounted to the engine dynamometer, shall be activated through the use of an air starter. An air compressor shall be provided to activate the starter. The air compressor shall be sized to allow 5 seconds of starting operation per minute.

1.2.6. Engine control module. All engine control modules shall be provided to test the engines in Table 1 on the engine dynamometer. The modules shall be powered and controlled through the dynamometer. These adapters shall exhibit plugs for connections wherever applicable.

1.2.7. Throttle control. The engine dynamometer shall control the throttle of the engine for both electronic and manual throttles. Controls shall be operated at the operator’s control station.

1.2.8. Shutoff. The engine dynamometer shall be equipped with an emergency shutoff in the control room.

1.2.9. Output. The engine dynamometer shall output a clearly marked test report, indicating all measured pass/fail parameters and the status of the test. The system shall print test reports utilizing standard 8.5 inch by 11 inch letter size paper.

1.2.10. Engine attachment. To move an engine into the area of attachment for the engine dynamometer, the engine shall be mounted on a cart. No fewer than 3 engine carts shall be supplied. All carts shall be identical, and rated to hold every engine that is required to be tested.

1.2.11. Cooling connections. The cooling system for the engine dynamometer shall use water. Fittings and hoses to adapt to local water, the tester, and each engine in Table I shall be supplied.

1.2.12. Fuel connection. The engine dynamometer shall exhibit a fuel storage unit. The fuel storage unit shall provide fuel to each engine at the rate and pressure required for that engine. The fuel storage unit shall exhibit a capacity no less than 50 gallons. The fuel storage unit shall exhibit the ability to roll for operation in various areas of the test cell. The pumps in the fuel storage unit shall self-prime. The fuel storage unit shall exhibit an interface that allows the tank to be filled manually through the use of cans or filling nozzles. All interface connections that connect the fuel storage unit to the engine and the dynamometer shall be supplied as stated in section 1.2.4. The fuel storage unit shall exhibit a gauge showing the fuel level in the storage unit.

1.2.13. Exhaust connection. The engine dynamometer shall include provisions to route the engine’s exhaust to the garrison’s existing exhaust system. Exhaust connection provisions to adapt to each item listed in the “Engine” column in Table I shall be included as adapters as stated in 1.2.4.

1.2.14. Control room. Each installation area for the engine dynamometer includes a control room. All controls and operation of the activated engine shall take place from the control room. Printing provisions shall be located in the control room.

1.3. Transmission dynamometer. The transmission dynamometer shall test all items listed in the “Transmission” column in Table I. Note that this includes both inline and cross-drive transmissions.

1.3.1. Tested parameters. The parameters measured by the transmission dynamometer shall include no less than the following: the transmission input and output speeds; the transmission input and output torque; stall torque; the main system and clutch pressure; electronic solenoid current and resistance; as well as the torque converter flow, temperature, inlet pressure, and outlet pressure. The transmission dynamometer shall measure the following additional parameters for cross-drive transmissions: left and right output speed; left and right output torque; lube pressure; PTO lube pressure; left and right brake pressure; left and right steer pressure; and Pitot pressure. The transmission dynamometer shall also allow the operator to check and set shift points.

1.3.2. Electronic control. The transmission dynamometer shall have an electronic control interface located on a control station. This interface shall display measured parameters in real time.

1.3.2.1. Output. The electronic controls of the transmission dynamometer shall output a clearly marked test report, indicating all measured pass/fail parameters and the status of the test. The system shall print test reports utilizing standard 8.5 inch by 11 inch letter size paper.

1.3.2.2. Control station. All controls and operation of the transmissions in Table I, including shifting, shall take place from the control station.

1.3.3. Adaptors. All adaptors including connectors, cables, plugs, mounting hardware, plates, covers, mounting brackets, lifting brackets, drive shafts, linkages, actuators, fittings, hoses, and other components necessary to properly control, connect, and test all transmissions in Table I shall be included with the transmission dynamometer. All items provided with the transmission dynamometer shall be stored in one or more cabinets specific to the transmission dynamometer.

1.3.4. Electric motor. The transmission dynamometer shall be powered by an electric motor rated for not less than 200 HP at a 100 percent duty cycle and have a rated full-load torque of not less than 585 foot-pounds.

1.3.4.1. Electrical service. The transmission dynamometer shall operate on established garrison power.

1.3.5. Transmission input. The transmission dynamometer shall be capable of driving the transmission input at infinitely variable speed range of not less than 0-3600 rpm in either direction.

1.3.6. Transmission output. The transmission dynamometer shall include not less than two air cooled power absorbers for load testing inline and cross drive transmissions.

1.3.6.1. Cross drive operation. Cross drive operation shall utilize two power absorbers. The power absorbers shall be positioned perpendicular to the transmission input on opposite sides of the cross drive transmission outputs.

1.3.6.2. Inline operation. Inline operation shall utilize one power absorber. The power absorber shall be positioned in line with the transmission output.

1.3.6.3. Power absorber specification. The power absorbers shall each have a maximum intermittent torque rating of not less than 1470 foot-pounds, a maximum continuous torque rating of not less than 525 foot-pounds, and a maximum input speed range of not less than 3000 RPM.

1.3.6.4. Stall torque. Each power absorber shall have a method of stall testing a transmission output to a maximum stall torque of not less than 2000 foot-pounds.

1.3.6.5. Height adjustment. The power absorbers shall be height adjustable to allow for mating of transmissions with different height centerlines.

1.3.7. Fluid. The transmission dynamometer shall include an onboard transmission fluid reservoir for clean fluid.

1.3.7.1. Heater cart. The transmission dynamometer shall include a standalone fluid reservoir heater cart with a capacity of not less than 50 gallons. The heater cart shall have an electric heater to pre-heat stored fluid to the recommended operating temperature of the transmission from room temperature in approximately 1 hour. The heater cart shall have standalone fluid filling, evacuation, and filtering capabilities.

1.3.7.2. Filling. The transmission dynamometer shall include a fluid fill system to fill transmissions with transmission fluid to recommended levels.

1.3.7.3. Filter. The fluid fill and fluid evacuation system shall each include a screw-on fluid filter. The filters shall have a micron filtering rating equal to or better than the micron rating recommended by the transmission OEM.

1.3.7.4. Sump. The transmission dynamometer shall include a sump to catch any spilled fluid during testing and draining the transmission after test.

1.3.7.4.1 Fluid evacuation system. The transmission dynamometer shall include a fluid evacuation system to pump fluid spilled or drained into the sump through the fluid filter and into the fluid reservoir.

1.3.8. Emergency shutoff. The transmission dynamometer shall include an emergency shutoff at the control station.

1.3.9. Compressed air supply. The transmission dynamometer shall not require a compressed air supply greater than 90 psi and 5 CFM.

1.4. General requirements. All general requirements apply to both the engine dynamometer and the transmission dynamometer.

1.4.1. Item identification plate. A plate containing the manufacturer, model number, and serial number shall be attached to each dynamometer.

1.4.2. Safety. Product safety signs and labels shall conform to ANSI Z535.4.

1.4.3. Mounting. The dynamometers shall be capable of mounting to the floor with bolts.

1.4.4. Power connection. The power connections to the dynamometers shall be completely enclosed in conduit.

1.4.5. Codes. All wiring shall be in accordance with the NFPA 70 National Electrical Code.