MIL-PRF-53051C.pdf

Comments, suggestions, or questions on this document should be addressed to U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or sent by email to usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

AMSC N/A FSC 4320

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

INCH-POUND

MIL-PRF-53051C

13 July 2017

SUPERSEDING

MIL-PRF 53051B

06 August 1998

PERFORMANCE SPECIFICATION

PUMPING ASSEMBLIES, WHEEL-MOUNTED, DIESEL ENGINE DRIVEN,

BULK TRANSFER, FUEL AND POTABLE WATER PUMPING SERVICE

This specification is approved for use by the U.S. Army Tank-automotive and Armaments Command, Department of the Army and is available for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This purchase description covers wheel-mounted, diesel-engine-driven, self-priming, four-inch and six-inch hose connection pumps for fuel or potable water service, hereinafter referred to as “pump assembly”.

1.2 Classification. The pump assemblies will be of the following types as specified (see 6.2).

Type I - Pump Assembly, Fuel

Size 1 - 350 gallons per minute (GPM) Capacity at 275 Feet Total Head

Size 2 - 600 GPM Capacity at 350 Feet Total Head (1250 GPM Capacity at 180 feet total head)

Type II - Pump Assembly, Water

Size 1 - 350 GPM Capacity at 275 Feet Total Head

Size 2 - 600 GPM Capacity at 350 Feet Total Head

2. APPLICABLE DOCUMENTS

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2.1 General. The documents listed in this section are specified in sections 3 and 4 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 and 4 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 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.

SPECIFICATIONS

FEDERAL

A-A-52624 - Antifreeze, Multi Engine Type A-A-59326 - Coupling Halves, Quick-Disconnect, Cam-Locking Type.

A-A-59592 - Can, Fuel, Military: 20-Liter Capacity.

DEPARTMENT OF DEFENSE

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

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4, JP-5, And JP-5/JP-8 ST.

MIL-PRF-10924 - Grease, Automotive and Artillery.

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

MIL-PRF-32143 - Batteries, Storage: Automotive, Valve Regulated, Lead Acid MIL-PRF-32349 - Container, Cargo Triple Container (TRICON)(Without

Cabinets, Drawers, or Shelves).

MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic.

MIL-DTL-64159 - Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant.

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

STANDARDS

DEPARTMENT OF DEFENSE

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

MIL-STD-130 - Identification Marking of U.S. Military Property.

MIL-STD-209 - Interface Standard for Lifting and Tiedown Provisions.

MIL-STD-461 - Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment.

MIL-STD-464 - Electromagnetic Environmental Effects Requirements for Systems.

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MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests.

MIL-STD-1179 - Lamps, Reflectors and Associated Signaling Equipment for Military Vehicles.

MIL-STD-1366 - Interface Standard for Transportability Criteria.

MIL-STD-1472 - Human Engineering.

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

(Copies of these documents are available from https://assist.dla.mil.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications 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.

CODE OF FEDERAL REGULATIONS (CFR)

CFR Title 40 - Protection of Environment.

(Copies of these documents are available from www.fdsys.gov.)

NORTH ATLANTIC TREATY ORGANIZATION (NATO)

AFLP-3747 - Guide Specifications for Aviation Turbine Fuels.

AMOVP-1 - Road Movements and Movement Control.

STANAG 1135 - Interchangeability of Fuels, Lubricants and Associated

Products Used by the Armed Forces of the North Atlantic Treaty Nations.

STANAG 4074 - Auxiliary Power Unit Connections for Starting Tactical Land Vehicles.

(Copies of these documents are available from https://assist.dla.mil.)

US ARMY PAMPHLETS

DA Pam 611-21 - Military Occupational Classification and Structure.

(Copies of this document is available online at usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil.)

US ARMY TECHNICAL MANUALS

TM 9-2320-211-10 - Truck, 5-Ton, 6x6, M39 Series (Multifuel), Operators Manual for.

TM 9-2320-260-10 - Truck, 5-Ton, 6x6, M809 Series (Diesel), Operators Manual for.

TM 9-2320-272-10 - Truck, 5-Ton, 6x6, M939, M939A1, and M939A2 Series Trucks (Diesel), Operators Manual for.

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TM 9-2320-366-10 - M1083 Series, 5 Ton, 6x6, Medium Tactical Vehicles (MTV), Operators Manual for.

TM 10-3930-643-10 - Truck, Forklift, DED Pneumatic Tire, 10,000 lb. Capacity, Rough Terrain, Articulated Frame Steer, (M10A), Operators

Manual for.

TM 10-3930-673-10 - All Terrain Lifter Army System (ATLAS), Clean Burn Diesel, 10,000 lb. Capacity, Operators Manual for.

(Copies of these documents are available online at http://www.usapa.army.mil.)

DRAWINGS

11674728 - Vehicle Receptacle Assembly, NATO Intervehicle Power.

11682336 - Cable and Plug Assembly, Intervehicle Power.

13219E0462 - Ground Rod

(Copies of these documents are available online at usarmy.detroit.rdecom.mbx.tardec-standardization@mail.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.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.1 - Unified Inch Screw Threads (UN and UNR Thread Form).

ASME B1.20.1 - Pipe Threads, General Purpose (Inch).

ASME B1.20.3 - Dryseal Pipe Threads (Inch) Revision and Redesignation of

B2.2-1968.

ASME BPVC IX - Boiler and Pressure Vessel Code (BPVC). Section IX

Qualification Standard for Welding, Brazing, Fuzing Procedures

(Copies of these documents are available online at http://www.asme.org).

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D 975 - Standard Specification for Diesel Fuel Oils.

ASTM D 1655 - Standard Specification for Aviation Turbine Fuels.

(Copies of these documents are available online at www.astm.org).

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1 - Structural Welding Code - Steel AWS D1.2 - Structural Welding Code Aluminum AWS D1.3 - Structural Welding Code - Sheet Steel

(Copies of these documents are available online at www.aws.org).

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HYDRAULIC INSTITUTE

ANSI/HI 14.6 - Rotodynamic Pumps for Hydraulic Performance Acceptance Tests

(Copies of this document is available at http://www.pumps.org/).

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

(Copies of this document is available online at http://www.nema.org).

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE-AMS-STD-595/33446 - Desert Tan 686A SAE-AMS-STD-595/37030 - Black SAE J513 - Refrigeration Tube Fittings, General Specifications SAE J614 - Engine and Transmission Dipstick Marking

SAE J847 - Trailer Tow Bar Eye and Pintle Hook/Coupler Performance SAE J2360 - Automotive Gear Lubricants for Commercial and Military Use

(Copies are of these documents are available at www.sae.org).

TIRE AND RIM ASSOCIATION, INC.

Tire and Rim Association Year Book

(Copies of this document is available online at www.us-tra.org).

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 First article. Unless otherwise specified (see 6.2), a sample shall be subjected to first article inspection in accordance with (IAW) 4.1.1.

3.2 Materials. The contractor shall verify that the materials used in the pump assembly are as identified and shall meet all of the operational and environmental requirements specified.

The components incorporated into the pump assembly shall be newly fabricated from recovered materials (see 6.6.1) to the maximum extent practicable, provided the components meet all other requirements of this document. Type I pump assemblies shall be constructed of materials suitable for fuel pumping service. Type II pump assemblies shall be constructed of materials suitable for potable water pumping service. Lead shall not be used. The finished Type II pump assembly shall contain no materials or substances that might leak or disintegrate and cause the pumped water to become non-potable. The material shall have no adverse effect on the health of personnel when used for its intended purpose. The lines and all surfaces that contact potable water shall conform to the applicable federal regulations for use with potable water.

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3.2.1 Deterioration prevention and control. The pump assembly shall be fabricated from compatible materials, inherently corrosion resistant or treated to provide protection against corrosion and deterioration during storage and operational conditions experienced.

3.2.2 Dissimilar metals. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion.

3.2.3 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. Used, rebuilt, or remanufactured components shall not be incorporated into the pump assembly.

3.2.4 Usage of COTS items. Commercial-off-the-shelf (COTS) items shall be used whenever available. COTS items shall not be modified unless absolutely necessary.

3.3 Operating requirements.

3.3.1 Pump assembly performance.

3.3.1.1 Hydrostatic pressure. The pump assembly shall be rated for a maximum operating pressure of 150 psig. The pump assembly, with the valves open and with couplers’ dust covers installed (see 3.3.2.3), shall withstand an internal hydrostatic pressure of 225 pounds per square inch gage (psig) for not less than 5 minutes without rupture or distortion to any component, and without leakage through the assembly, fittings, piping, or joints.

3.3.1.2 Capacity. The pump assembly shall meet the rated flow capacities indicated below using water at standard conditions, as specified by the Hydraulic Institute ANSI/HI 14.6 Centrifugal Pumps and Tests. Rated flow rates are as follows:

a. Type I, Size 1 - 350 gpm with a total dynamic head of 275 feet.

b. Type I, Size 2 - 600 gpm with a total dynamic head of 350 feet, and

1250 gpm with a total dynamic head of 180 feet.

c. Type II, Size 1 - 350 gpm with a total dynamic head of 275 feet.

d. Type II, Size 2 - 600 gpm with a total dynamic head of 350 feet.

3.3.1.2.1 Tilting. The pump assembly shall perform at rated flow as specified in 3.3.1.2 when tilted a minimum of 15 degrees from horizontal in any direction.

3.3.1.3 Pump priming. The pump assembly shall prime automatically, after initial filling of the case, and deliver not less than the rated flow (see 3.3.1.2) in not greater than 2 minutes, when operating at a static suction lift equivalent to 10 ft at sea level and atmospheric conditions of 29.92 inches of mercury, using water with a specific weight of 62.3 pounds per cubic foot (lbs/ft3) at 68 degrees Fahrenheit (°F).

3.3.1.4 Slope capability. The pump assembly shall be capable of negotiating a minimum of 20 percent (%) side slopes; and approaching, negotiating, and departing a ramp of a minimum 30% slope without ground contact of any component (except the tires), and without contact of the tires with any other part of the assembly.

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3.3.1.5 Mobility. The pump assembly, when towed by any designated prime mover (see 3.3.1.5.1), shall have mobility not less than that described below without malfunction, permanent deformation, or damage.

3.3.1.5.1 Prime movers. The pump assembly shall be capable of being towed by standard US Army 5-ton Series Tactical Cargo Trucks of the types and series described below:

a. M39 Series, TM 9-2320-211-10.

b. M809 Series, TM 9-2320-260-10.

c. M939 Series, TM 9-2320-272-10.

d. M939A1 Series, TM 9-2320-272-10.

e. M939A2 Series, TM 9-2320-272-10.

f. M1083 Series “FMTV”, TM 9-2320-366-10.

3.3.1.5.2 Mobility.

a. Improved (paved) roads at an average speed of 20 miles per hour (mph).

b. Unimproved (unpaved) roads at an average speed of 10 mph.

c. Over cross country terrain at an average speed of 8 mph.

3.3.1.6 Drop. The pump assembly shall be capable of withstanding drops of 26 inches, measured from the lunette to the ground, onto its lunette and frame, about its axle (see 3.3.2.9) without permanent damage, deformation, or any degradation in performance.

3.3.1.7 Fording capability. The assembly shall be capable of fording in water to a depth of not less than 30 inches, without modification or kits, without damage or degradation in performance.

3.3.2 Pump assembly characteristics and components. All threaded parts shall conform to ASME B1.1, ASME B1.20.1, or ASME B1.20.3, as applicable.

3.3.2.1 Pump housing. The pump housing shall be provided with a minimum 1.5-inch priming port with locking cap, for filling the pump housing without removal of the suction or discharge connections. The pump housing shall be provided with a drain port and manual valve for draining the case without tilting, and capable of being fully drained in five (5) minutes or less. The valve discharge shall be routed for easy accessibility and to allow for collection of the discharge and prevent spillage into the environment (see 3.3.2.8.1 and 3.5.3). The priming port shall be equipped with a male, quick-disconnect, coupling and captive dust cap with gasket IAW A-A-59326.

3.3.2.2 Piping and fittings. All piping and fittings shall be mounted securely and shall withstand an internal working pressure of 150% of the shutoff pressure or maximum operating pressure, whichever is higher, at rated speed without leaking or deformation. The discharge piping shall contain a vent valve, with 0.25-inch NPT thread IAW ASME B1.20.1, to remove air during priming. The vent shall be located at the highest point in the discharge piping. The vent valve discharge shall be routed for easy accessibility and to allow for collection of the discharge and prevent spillage into the environment (see 3.3.2.8.1 and 3.5.3).

3.3.2.3 Suction and discharge components. The pump assembly shall have the following suction and discharge components:

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a. Discharge check valve, having a flanged housing of a durable, light-weight, corrosion resistant, non-magnetic material, suitable to the application and compatible with discharge housing.

b. A six-inch valve and a four-inch valve shall be incorporated on the suction port, and on the discharge port, of the pump. The valves shall be supported by brackets connected to the assembly chassis, and shall be labeled to indicate the open-close direction. The valves shall be positioned to accept both hose and pipe.

c. The suction side of the pump shall terminate in a six-inch and a four-inch, female, quick-disconnect couplings with gaskets IAW A-A-59326, Class A, fitted with tethered dust plugs IAW A-A-59326/11, Class A.

d. The discharge side of the pump shall terminate in a six-inch and a four-inch, male, quick-disconnect couplings IAW A-A-59326, Class A, fitted with tethered dust caps and gaskets IAW A-A-59326/10, Class A.

e. A suction strainer assembly, consisting of a 0.25 inch mesh, in-line type, reinforced basket strainer of a durable, rigid, corrosion resistant material suitable to the application.

3.3.2.4 Engine. The engine shall be rated by the manufacturer for continuous power duty adequate to power the assembly to meet the performance requirements of 3.3.1.2. The engine shall meet the performance requirements herein with JP-8 as the primary fuel (see 3.4.3).

Diesel engines shall have an EPA emission certification for non-road diesel engines as required by CFR Title 40 Parts 9, 86, and 89 at its power rating. The engine shall be equipped with, but not limited to, the following items:

a. A nominal 24-volt direct current (VDC) electric cranking system.

b. An electrical charging system.

c. A heavy duty, dry type, air cleaner with replaceable cartridge.

d. Fuel filters: primary, water-separating type, and secondary (final); each with provision for drainage into an external container (see 3.3.2.8.1).

e. Exhaust system with guard and rain cap.

f. Engine oil drain, easily accessible for maintenance and to minimize the potential for spillage to the environment (see 3.5.3).

g. Heavy duty cooling system capable of maintaining the manufacturers recommended operating temperature when performing at maximum rated capacity as specified herein. If liquid-cooled, the engine shall operate with antifreeze IAW A-A-52624;

cooling system overflow reservoir shall be included for liquid-cooled engines, to prevent coolant discharge into the environment (see 3.5.3).

h. Engine rotating and moving parts guard, providing reliable, quick, and easy access for maintenance, and requiring no tools for removal or installation.

i. Oil dipstick conforming to SAE J614.

3.3.2.5 Electrical system. The starting, charging and lighting systems, and all electrical components of the assembly shall be nominal 24 VDC. A temperature-compensated, integral charging system, wiring, and battery(s) shall be supplied to provide starting, lighting, and additional electrical power as needed to (a) recharge the battery(s) in not more than 30 minutes of continuous operation after the system has been started three times at -25°F, and (b) start the

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3.3.2.5.1 Batteries. All batteries shall be US Army approved IAW MIL-PRF-32143.

Batteries shall be readily accessible for service and inspection and shall be of sufficient quantity and type to comply with the starting, lighting, normal and surge electrical loads, reserve electrical power capacity, and maintenance requirements.

3.3.2.5.2 Battery cables. The positive cable(s) shall have a non-conductive red sleeve at both ends. The negative cable(s) shall have a black non-conductive sleeve on both ends. A battery terminal non-conductive protective cover shall be provided on each battery terminal connector (red for positive and black for negative). The battery cables shall be marked to indicate polarity.

3.3.2.5.3 Battery box. A vented battery box shall be provided to retain/protect the batteries during operation and transport. The box shall allow for easy installation and removal of the batteries. The box shall protect the batteries from external environmental conditions and shall provide for venting of battery gases at or near the top of the box. The box shall be resistant to battery electrolyte. Means shall be provided to allow drainage out of the bottom of the box, regardless of incline.

3.3.2.6 Control and Instrument panels. A control panel and an instrument panel shall be provided for the pump assembly. The control and instrument panels shall be covered by a latching door(s) with automatically engaging hold-open devices. The panels shall each contain a switch that automatically turns off the lights when the panel door is closed. All panel face components shall be labeled and legible by the operator.

3.3.2.6.1 Control panel. The control panel shall be of modular design and meet the requirements for NEMA 250 Type 4 X enclosures. The control panel shall be replaceable in under 10 minutes using no special tools (see 6.6.5). The control panel shall include the following as a minimum:

a. Power ON/OFF toggle circuit breaker and indicator light.

b. Assembly OFF/RUN/START toggle switch and indicator light.

c. Glow plug power toggle switch (momentary) and indicator light.

d. Mode selector switch (3 position; MANUAL/SPEED/PRESSURE).

e. RAISE/HOLD/LOWER toggle switch (return to center).

f. Suction pressure limit override toggle switch and indicator light.

g. Engine shutdown indicator(s).

h. Battle short bypass toggle switch and indicator light.

i. Voltmeter.

j. Ammeter.

k. EMERGENCY STOP pushbutton, readily accessible in case of emergency, even if control panel door is closed.

3.3.2.6.1.1 Control panel components. The control panel face components in 3.3.2.6.1 shall be sealed against the environmental effects of 3.6.3 (Sand) through 3.6.8 (Salt fog).

Components located in the control panel shall only be electrical components. Discrete visual

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3.3.2.6.1.2 Engine/pump protection. The engine and pump of the assembly shall be provided with automatic protections resulting in engine shutdown. A manual reset shall be required following an automatic shutdown; toggling the assembly OFF/RUN toggle switch is acceptable. All alarm and shutdown circuits shall be designed fail-safe; a shutdown condition, sensor failure, broken wire, blown fuse, etc. shall result in an engine shutdown. Engine/pump protections shall include the following shutdown conditions as a minimum:

a. Engine over speed (exceeding 110% of maximum engine rated speed).

b. High engine temperature.

c. High fuel tank temperature (exceeding 175 degrees F).

d. Low engine oil pressure.

e. Excessive discharge pressure (exceeding 110% of rated discharge pressure, see

3.3.1.2)

3.3.2.6.1.3 Shutdown annunciation. Shutdown annunciation shall be provided for the engine/pump protections of 3.3.2.6.1.2. A unique indication shall be provided for each shutdown condition and each sensor failure. A diagnostic or start-up check shall be provided allowing the operator to verify that the shutdown indicator(s) is(are) functional.

3.3.2.6.1.4 Emergency shutdown capability. The pump assembly shall be equipped with a reliable, fail-safe, remote emergency shutdown capability. Operator shall have the ability to shut down the engine/pump beyond a 15 foot perimeter of the pump assembly. The remote emergency shutdown shall be capable of secure mounting on the ground rod (see 3.5.5.2), to be readily available for use and not resting on the ground surface.

3.3.2.6.2 Instrument panel. Components located in the instrument panel shall only be mechanical type components. The instrument panel shall include the following as a minimum:

a. Suction pressure gauge of the Bourdon type, compound with a minimum range of 30 inches Hg (mercury) vacuum - 0 psig - 200 psig.

b. Discharge pressure gauge of the Bourdon type, with a minimum range of 0 - 200 psig.

c. Mechanical tachometer-hour meter.

d. Mechanical engine oil pressure gauge.

e. Mechanical engine temperature gauge.

f. Air filter restriction indicator.

g. Manual throttle.

3.3.2.6.3 Pressure lines. Any process lines that provide process fluid to the instrument panel shall be minimum 0.25 inch stainless steel tubing with short runs of stainless steel braided hoses in areas that require movement (vibration isolation). Readily accessible drainage cocks shall be provided as required and lines shall be mounted to provide complete drainage for storage and transport. The discharge shall be routed for easy accessibility and to allow for collection of the discharge and prevent spillage into the environment (see 3.3.2.8.1 and 3.5.3).

3.3.2.7 Automatic pump controller. The assembly shall include controls for placing the pumping assembly in three different modes of operation: manual, automatic pressure control, and automatic speed control. In either of the automatic controller modes, the assembly shall be

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Not for Resale, 08/30/2018 09:57:41 MDTNo reproduction or networking permitted without license from IHS equipped to reduce engine speed to limit high discharge pressure or low suction pressure. The automatic controller shall sense the discharge pressure and begin to reduce engine speed at 150 psig. If discharge pressure continues to increase, the controller shall continue to reduce engine speed until the idle setting is reached. To prevent pump cavitation and damage to the pump and engine, the automatic controller shall also sense the pressure on the suction side of the pump. If suction pressure falls to 10 psig, the controller shall begin reducing engine speed. If suction pressure continues to decrease, the controller shall continue to reduce engine speed until the idle setting is reached. The controller shall be capable of being turned off in the manual mode so that engine speed is regulated via the manual throttle.

3.3.2.7.1 Manual mode. When operating in manual mode, the automatic controller features of 3.3.2.7 shall be overridden by the manual throttle. The manual throttle shall control engine speed via manual and mechanical means acting directly on the engine original equipment manufacturer (OEM) component(s) (preferably acting on mechanical governor).

3.3.2.7.2 Automatic speed control mode. When operating in automatic speed control mode, the RAISE/HOLD/LOWER toggle switch of 3.3.2.6.1 shall be used to adjust engine speed from the minimum (idle) to the maximum operating speed. The automatic pump controller shall control the engine speed to the selected setting. The automatic pump controller of 3.3.2.7 shall override the selected setting if high discharge pressure and/or low suction pressure limits are reached.

3.3.2.7.3 Automatic pressure control mode. When operating in automatic pressure control mode, the RAISE/HOLD/LOWER toggle switch of 3.3.2.6.1 shall be used to adjust discharge pressure from the minimum to the maximum operating discharge pressure. The automatic pump controller shall control the engine speed to meet the selected discharge pressure.

The automatic pump controller of 3.3.2.7 shall override the selected setting if high discharge pressure and/or low suction pressure limits are reached.

3.3.2.7.4 Suction pressure limit override. The assembly shall be capable of operating in either of the automatic controller modes with the low suction pressure limit enabled or disabled.

The low suction pressure limit shall be enabled or disabled via the suction pressure limit override toggle switch located on the control panel of 3.3.2.6.1.

3.3.2.7.5 Battle Short bypass. The assembly shall include a battle short bypass. This feature shall bypass any engine shutdown controls that would normally remain operational when the assembly is in manual mode, including those of 3.3.2.6.1.2, for operation of the assembly with a damaged control panel in a battlefield environment. This feature shall have an indicator, with label, on the face of the control panel to signal the operator(s) that the bypass is engaged.

3.3.2.8 Fuel system. A fuel tank, sufficient for not less than 8 hours of continuous operation at the engine manufacturer’s maximum rated load, shall be furnished. A fuel gauge shall be provided, graduated in ¼-tank increments, minimum, from empty to full, and located on the fuel tank. The fuel tank shall include a hand-operated fuel shutoff valve with an arrow showing the directions of valve operation. The fuel tank pickup tube shall be from 0.50-inch to 1-inch above the bottom of the tank. The non-plastic fuel line shall be provided with a 3-way fuel selector valve and a 0.50-inch SAE J513 flared fitting for connection to an auxiliary fuel supply. A corrosion-resistant circular metal face-plate for the fuel selector valve shall be marked "OFF", "UNIT TANK" and AUXILIARY". No fuel spillage shall occur when the fuel tank is

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Not for Resale, 08/30/2018 09:57:41 MDTNo reproduction or networking permitted without license from IHS full and the assembly is operating IAW 3.3.1.2. The body of the fuel tank shall be fabricated from non-metallic material; corrosion-resistant metallic inserts may be used at connection points, interfaces, and ports. Surfaces shall be designed to shed water and moisture regardless of incline (see 3.6.7). The fuel tank shall be protected from damage by stones and other projectiles when in tow.

3.3.2.8.1 Fuel reservoir. One Military Fuel Can, 5 gallon (20 Liter) capacity, IAW A-A- 59592 shall be included with each pump assembly. Mounting for the fuel reservoir on the pump assembly shall be provided; Bracket Assembly, A-A-52513, is provided as reference only. The fuel can shall be used to receive fuel discharge from the vent valve (see 3.3.2.2) and pressure lines (see 3.3.2.6.3) when operating a Type I (fuel) pump assembly, and for minor refueling of the fuel system (see 3.3.2.8). The fuel reservoir shall include an additional cap to be used when the pump assembly is in operation. The additional cap shall allow for venting of pressure, prevent dirt and contamination from entering the fuel reservoir, and have connections for the vent valve discharge routing (see 3.3.2.2) and pressure line drainage (see 3.3.2.6.3).

3.3.2.8.2 Refueling from pumped fluid. The Type I (fuel) pump assembly shall be equipped with the capability of refueling (filling of the fuel tank) from the pumped fluid while pumping; the Type II (water) pump assembly shall be prohibited from having this capability. A manual valve shall be included at the discharge of the pump, and a fail closed, hold to open, valve at the fuel tank. The design shall result in safe refueling under all operating conditions.

3.3.2.9 Chassis. The pump assembly components shall be mounted on a chassis having two single wheels, on an axle assembly attached to the underside of the assembly frame. The axle and chassis assembly shall have a rated capacity exceeding the maximum payload, but not less than 6000 lbs. The chassis shall be equipped with a minimum of two shock absorbers for stability.

3.3.2.9.1 Tires and wheels. Tires and wheels shall be IAW the guidelines of the Tire and Rim Association Year Book and shall be of sufficient size and durability to support loads in off-road conditions. Tire pressure shall be indicated directly above the tires in 1-inch high letters.

3.3.2.9.2 Brakes. The pump assembly shall be equipped with parking brakes capable of keeping the assembly from moving down a 25% slope. The parking brake shall be manually operated with snap-over-center locking design. The force required to apply the parking brake shall not exceed 35 lbs. The parking brake handle shall be accessible to the operator. All cables and brake lines shall be routed to not interfere with the free movement of other components. The brake lines and all cables shall be securely clamped along the routing path and routed to avoid brush and debris damage.

3.3.2.9.3 Towing extension. The pump assembly shall have a towing eye (lunette) IAW SAE J847 with a nominal height of 26-inch when the unit is level and on a level surface. Weight on the towing eye with the fully-fueled assembly parked on level ground shall be not greater than 15% and not less than 10% of the gross weight of the assembly. When necessary, the assembly shall be equipped with retractable towing extensions capable of easy extension for towing and easy retraction for storage.

3.3.2.9.4 Stabilizing legs. The pump assembly shall be equipped with an adjustable, hand-crank style jack to permit operation of the towing extension by one person (see 3.5.2 and

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3.7). Hand-crank style stabilizing legs shall be provided to permit assembly operation without tipping over when not attached to the designated prime mover (see 3.3.1.5.1). The jack and stabilizing legs shall each be equipped with a sandshoe with a minimum area of 150 square inches (in2). When not in use, the jack and stabilizing legs shall be positioned in such a way as to not affect the towing of the assembly. The jack and legs shall each have a minimum travel of 10-inches.

3.3.2.9.5 Lights, reflectors and connector. Pump assembly shall be equipped with reflex reflectors IAW MIL-STD-1179.

3.4 Interface requirements.

3.4.1 Transportability. The pump assembly shall be capable of being transported by military or commercial tractors, tractor/trailer combinations, trains (rail), marine vessels, and aircraft per MIL-STD-1366 and 3.4.1.6. The pump assembly shall be equipped with tiedown and slinging provisions. The pump assembly shall be capable of withstanding the impact forces encountered in shipment without damage or permanent deformation.

3.4.1.1 Tiedown provisions. The pump assembly shall be equipped with tiedown provisions IAW MIL-STD-209. The tiedown provisions shall restrain the components without weld failure, permanent deformation, cracking, loosening, or breaking of the provision or its connecting structural components.

3.4.1.2 Slinging provisions. The pump assembly shall be equipped with slinging provisions IAW MIL-STD-209, and shall be located so that at least 1-inch clearance is maintained between slings and all exterior parts. Reinforcement may be fastened to members that shall withstand stresses, consistent with the amount and direction of pull. Slinging provisions may also be used as tiedown provisions when such provisions meet the requirements specified in 3.4.1.1. All slinging/tiedown provisions shall be labeled "LIFT", “TIEDOWN", or "LIFT TIEDOWN", as appropriate, in 1-inch (2.54 cm) high letters.

3.4.1.3 Rail transport. The pump assembly shall be rail transportable, in both a TRICON transport configuration and a stand-alone configuration, in the U.S. and North Atlantic Treaty Organization (NATO) countries without restriction. The pump assembly shall have a dimensional profile within the Gabarit International de Chargement (GIC) outline diagram (see MIL-STD-1366) when loaded aboard a 50-in high rail car.

3.4.1.3.1 Rail impact. The pump assembly, packed in TRICON for transport and stand-alone configuration, shall be capable of withstanding shock loads resulting from rail shipment or railroad car impacts as described in MIL-STD-810, without failure, damage, permanent deformation, or reduction in operational or design capability.

3.4.1.4 Highway transport. When transported on commercial or non-tactical military vehicles, the pump assembly shall be within the highway permit limits for all U.S. states and the general unrestricted transport in NATO countries IAW MIL-STD-1366 and AMOVP-1, not to exceed 4 meters in height (see 6.7).

3.4.1.5 Marine transport. The pump assembly shall be transportable by commercial ships and barges, and Army landing craft and barges.

3.4.1.6 Aircraft transport.

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3.4.1.6.1 Fixed-wing aircraft. The pump assembly shall be internally transportable by United States Air Force (USAF) C130 fixed-wing aircraft, and larger commercial and USAF aircraft (see MIL-STD-1791 for guidance).

3.4.1.6.2 Rotary-wing aircraft. The pump assembly shall be transportable by United States Army CH47 rotary-wing aircraft.

3.4.1.7 Forklift. The pump assembly shall include forklift pockets that are capable of safely lifting 10,000 lbs with 48-inch load centers and at least 72-inch tines, for use with standard Army 10,000 pound forklifts: All Terrain Lifter Army System (ATLAS) (TM 10-3930-673-10), and Articulated Frame Steer Forklift Truck (M10A) (TM 10-3930-643-10). The maximum spread, on center, of the forklift pockets shall be 28 inches, to interface with standard Army 4,000 pound forklifts.

3.4.2 NATO intervehicle receptacle. A receptacle conforming to NATO STANAG 4074 Type 1 (see also 6.8) with cover shall be provided. The receptacle shall be located in a protected position, and connected in parallel with the battery(s), to allow the pump assembly to accept electrical power from another nominal 24 VDC military system through a NATO intervehicle cable and plug assembly (see 6.8). The receptacle shall be labeled "24 VOLTS". The receptacle shall provide the capability of starting and running the pump assembly without pump assembly batteries.

3.4.3 Fuel. The pump assembly shall be capable of operating on all military and commercial kerosene based fuels conforming to, as a minimum, those listed below without restrictions or kits. JP-8 shall be the designated primary fuel for engine operation.

a. MIL-DTL-83133 (JP-8) (NATO F-34) (see 6.9)

b. MIL-DTL-5624 (JP-5) (NATO F-44) (see 6.9)

c. ASTM-D975 (Diesel-US commercial)

d. MIL-DTL-83133 (NATO F-35) (see 6.9)

e. ASTM-D1655 (Jet A-1)

f. AFLP-3747 (NATO F-24) (see 6.9)

3.4.4 Lubricants. The pump assembly, depending on the ambient temperature, shall be limited to the use of one or more of the following lubricating oils: MIL-PRF-2104, MIL-PRF- 46167, and MIL-PRF-21260. Gear oil, if required, shall conform to SAE J2360, and grease to

MIL-PRF-10924.

3.4.5 Dimensional and weight limits. Pump assembly shall weigh no greater than 4000 pounds and fit within the dimensions of 88.00 inches long (a retractable tow bar may be used),

72.00 inches wide, and 82.00 inches high. The pump assembly design shall permit loading into a

TRICON IAW MIL-PRF-32349.

3.5 Ownership and support requirements.

3.5.1 Safety. All electrical wiring and any rotating or reciprocating parts shall be electrically and physically safe, and shall be guarded so as not to be a hazard to operating personnel and to minimize the hazard of fire in the event of a fuel spillage or leakage from hoses and connections. All electrical terminals shall be completely enclosed or insulated to prevent inadvertent contact by personnel or equipment that may cause arcing to occur. An emergency

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Not for Resale, 08/30/2018 09:57:41 MDTNo reproduction or networking permitted without license from IHS shutoff device shall be located at the operator station(s) for the assembly, to quickly and completely shut off/stop flow and the engine in case of accident, malfunction, or potential safety hazard. Danger or caution signs, labels and markings shall be used to warn of potential or specific hazards.

3.5.2 Human factors engineering. Human engineering criteria, principles, and practices shall be IAW MIL-STD-1472. The pump assembly shall be capable of being operated by the 5th percentile female to the 95th percentile male military personnel wearing gloves, arctic mittens, or equipped with Mission Orientated Protective Posture (MOPP) IV gear (see 6.6.2) without special tools or support equipment. Emphasis shall be given, but not limited to, general requirements, control and display integration, controls, labeling, maintainability, anthropometry, and hazard and safety criteria, as applicable.

3.5.3 Environmental hazard prevention. Provisions shall be made and included to prevent fluid leakage and safely contain leakage and spillage during all storage, transport and operational use of the pump assembly. The pump assembly shall comply with all US HAZMAT, OHSA, safety and transportation requirements, regarding prevention of inadvertent fuel discharge or leakage during operation, storage, and maintenance.

3.5.4 Lighting. All components of the pump assembly shall be effectively operable by the operator in reduced visibility, nighttime, and blackout conditions. All lighting shall be of the light emitting diode (LED) type in lieu of incandescent bulbs.

3.5.4.1 Lighting, non-tactical. Permanent or detachable lighting shall be provided to insure safe operation of the assembly in darkness and periods of reduced visibility.

3.5.4.2 Lighting, tactical/blackout operations. Blackout lighting provisions shall meet the following requirements:

a. A single blackout switch, labeled “BLACKOUT SWITCH”, shall control all light sources.

b. When blackout lighting is activated, ninety-five % of the light energy emitted by each light source shall be at wavelengths below 700 nanometers.

c. When blackout lighting is activated, all light sources shall be dimmed to 0.05 ft- Lamberts (fL), 0.17 candela per square meter, or less.

3.5.5 Grounding and bonding.

3.5.5.1 Bonding. The assembly shall provide complete electrical continuity throughout the unit, and shall include a metal-to-metal contact from the assembly to the ground. This includes all electrically conductive components of the unit that the operator and/or fuel may come in contact with. All bonding and/or grounding connections shall be mechanically secure and shall measure 1 (one) ohm or less.

3.5.5.2 Grounding rods, wires and clamps. For each pump assembly, a grounding rod shall be provided IAW drawing 13219E0462. A grounding wire with a minimum length of 20 feet shall be provided and equipped with a manual clamp requiring no tools for grounding the pump assembly during operation. The grounding wire shall be provided on a manual retracting reel mounted on the pump assembly. The pump assembly shall include stowage/storage provisions for all grounding components.

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3.5.6 Reliability. The mean-time-between-failures (MTBF) (see 6.6.3) of the assembly shall be not less than 200 hours at the 80% lower confidence level.

3.5.7 Maintainability. The assembly shall provide easy access to components requiring repair, replacement, routine or frequent maintenance or adjustment. The median time to repair (MedTTR) shall not exceed 1.5 hours for all unscheduled maintenance actions, and the maximum time to repair shall not exceed 3.0 hours for 90% of unscheduled maintenance actions (Max TTR90). All major assemblies and installed attachments requiring repair, replacement, and adjustment shall be accessible without the removal of other major components. Drain outlets shall be located for accessibility. All drain plugs and filler caps shall be durable and shall be permanently attached to the unit without impeding their removal. Corrosion resistance preventive maintenance shall be limited to routine washing, periodic inspection and repair of accident damage.

3.5.7.1 Maintenance ratio. The assembly shall have a maintenance ratio (see 6.6.4) of not greater than 0.07. Man-hours for repair of replaced components, and operator level, before-and-after-operation preventive maintenance checks and services (PMCS) are excluded.

A maintenance schedule shall be established prior to start of any testing.

3.5.8 Operator equipment. All tools, special tools, and test equipment required to perform operator-level Preventive Maintenance Checks and Services (PMCS) (see 6.6.6) shall be provided with each system along with the required stowage space (see 3.5.9).

3.5.9 Storage container. A storage container shall be rigidly mounted on the assembly.

The container shall be watertight when closed. The container shall be of a size capable of storing the items specified in 3.5.8 and 3.5.9.1.

3.5.9.1 Spares. Each pump assembly shall include the following accessories. Unless otherwise specified (see 6.2), each accessory shall be boxed or packaged separately and stored in the storage container of 3.5.9.

a. Set of engine oil filter(s).

b. Set of engine fuel filters(s).

c. Set of air filter(s).

d. Set of accessory/drive belt(s).

e. Eight (8) total quick-disconnect coupling gaskets IAW A-A-59326, of the appropriate sizes (see 3.3.2.3).

f. Funnel for priming port (see 3.3.2.1), with minimum 0.75 inch diameter spout.

g. US Army approved Technical Manual for the assembly.

3.5.10 Triple Container (TRICON). When specified (see 6.2), the pumping assembly shall include, and be packed in, a TRICON IAW MIL-PRF-32349.

3.6 Environmental requirements.

3.6.1 Operational temperature. The assembly shall operate as specified at any ambient temperature from -25°F to +120oF.

3.6.2 Storage temperature. The assembly shall not be damaged by storage in any ambient temperature from -30oF to +160oF with…