Attachment_3.pdf

PDF 2 MB Posted Jun 11, 2018

Attached to: M160 Engine Remanufacture
Solicitation number: W56HZV18R0151
Issued by: Department of the Army Materiel Command Contracting Command Detroit Arsenal

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Attachment_0003_Perkins_Engine_Specification.pdf	PDF	May 2, 2019
Attachment_0001_TM_9-2360-392-23P_0002_Excerpt.pdf	PDF	May 2, 2019
Attachment_0002_Parts_making_up_the_list_VK38244.pdf	PDF	May 2, 2019
Attachment_0004_Special_Packaging_Instructions__(SPI_AK15987019),_Revision_A,_Dated_20_June_2012.pdf	PDF	May 2, 2019
Attachment_1.pdf	PDF	Jun 11, 2018
Attachment_2.pdf	PDF	Jun 11, 2018
Attachment_1.pdf	PDF	May 31, 2018
Attachment_2.pdf	PDF	May 31, 2018
Attachment_3.pdf	PDF	May 31, 2018

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DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 1 of 13 Designed using Perform Pro, WHS/DIOR, Jun 97

SPECIAL PACKAGING INSTRUCTION

Form Approved OMB No. 0704-0188

-BK

The public reporting burden for this collection of information is estimated to average 30 days per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to the Department of Defense, Executive Services and Communications Directorate (0704-0188). Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR COMPLETED FORM TO THE ABOVE ORGANIZATION.

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

. VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012 A

7. QUP 8. ICQ 9. UNIT PACK WT (LB.) 10. UNIT PACK CU (CU. FT.) 11. UNIT PACK SIZE (INCHES)

1 EACH NONE 1639.0 62.998 58.3 X 38.5 X 48.5

12. MILITARY PRESERVATION 18.

STEPS

19.

REQD

20.

DESCRIPTION

MIL-STD-2073-1D, METHOD 53

13. CLEANING 1 – B A/R SPECIAL EQUIPMENT FOR ENGINE PRESERVATION

MIL-STD-2073-1D 2 – C A/R ENGINE PRESERVATION

14. DRYING 3 – D A/R CAPS/PLUGS: NAS-847

MIL-STD-2073-1D 4 – E 4 FABRICATED BRACKETS

15. PACKING

5 – F A/R HARDWARE

6 – G 4 BLOCKING/BRACING: ASTM-D6199, CL 3

a. LEVEL A

7 – H 1 WRAP: MIL-PRF-121, TY II, SIZE: 60 X 168

MIL-STD-2073-1D & NOTE M 8 – I 1 CUSHIONING: A-A-59135, CL 1, GR A,

b. LEVEL B

SIZE: 36 X 212 X ¼” THICKNESS

NOT APPLICABLE 9 – J 96 DESICCANT: MIL-D-3464, TY II

16. MARKING 10 – K 1 BAG: MIL-DTL-6060E, SIZE: 80 X 132 (FLAT LAYOUT)

MIL-STD-129 & NOTE N 11 – L 1 CONTAINER: ASTM-D7478, TY II, CL 2, ST A,

SIZE: 55-1/2 X 36 X 38

17. NOTES/DRAWING

A. INSPECT THE PRESERVATION AND UNIT PACK IN ACCORDANCE WITH MIL-STD-2073-1. INSPECT THE PACKING IN ACCORDANCE WITH MIL-STD-1186 AND THE APPLICABLE CONTAINER SPECIFICATION.

B. SPECIAL EQUIPMENT REQUIRED FOR ENGINE PRESERVATION (SEE PAGE 4):

1. ONE (1) PRESERVATIVE SUPPLY HOSE, APPROXIMATELY 24” IN LENGTH, OF WHICH ONE END SHALL BE EQUIPPED WITH A FITTING THAT WILL MATE WITH THE FUEL INLET FITTING LOCATED

ON THE FUEL PUMP.

2. ONE (1) PRESERVATIVE RETURN HOSE, 3/8” I.D. AND APPROXIMATELY 24” IN LENGTH, OF WHICH ONE END SHALL BE EQUIPPED WITH A FITTING THAT WILL FIT THE FUEL RETURN LINE OUTLET.

3. ONE (1) 24 VOLT D.C. POWER SUPPLY TO POWER THE STARTER MOTOR WITH SWITCH TO

ENGAGE/DISENGAGE THE STARTER SOLENOID.

4. ONE (1) SLAVE FUEL FILTER (PERKINS P/N 26560141).

5. TWO (2) SLAVE OIL FILTERS (PERKINS P/N 2654403).

6. ONE (1) FUEL FLOW CHECKING TOOL GROUP (CATERPILLAR P/N 331-3626) OR AN AIR

COMPRESSOR (MAX 15 PSI) WITH A SPRAYER ATTACHMENT ABLE TO PROVIDE SPRAY AND FOG

PATTERNS.

7. ONE (1) 5 GALLON PAIL OR EQUIVALENT FOR PRESERVATIVE DRAINAGE.

C. THE FOLLOWING PROCEDURE DESCRIBES THE APPROVED METHOD FOR PRESERVATION OF THIS

ENGINE:

ANY DEVIATIONS FROM THIS PROCEDURE SHALL BE PRE-APPROVED BY TACOM AND THE

ENGINE MANUFACTURER.

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 2 of 13

SPECIAL PACKAGING INSTRUCTION (Continuation Sheet)

Form Approved -BK OMB No. 0704-0188 MB

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012 A

1. REPLACE FUEL FILTER (P/N 26560141) AND OIL FILTERS (P/N 2654403) WITH SLAVE FILTERS. SET

ORIGINAL FILTERS ASIDE TO BE RE-INSTALLED AFTER PRESERVATION PROCESS IS COMPLETE

(SEE PAGE 5).

2. FILL PRESERVATIVE PUMP WITH ONE (1) GALLON OF PRESERVATIVE CONFORMING TO MIL-PRF-

21260E, TYPE PE-10. ATTACH PRESERVATIVE SUPPLY HOSE TO PRESERVATIVE PUMP OUTLET.

3. REMOVE CAP FROM FUEL PUMP INLET HOUSING, INSTALL PRESERVATIVE SUPPLY HOSE FROM

PRESERVATIVE PUMP TO FUEL INLET (SEE PAGE 6).

4. REMOVE CAP FROM FUEL RETURN LINE, ATTACH PRESERVATIVE RETURN HOSE, POSITION HOSE

OVER PRESERVATIVE DRAINAGE CONTAINER (SEE PAGE 7).

5. PUMP ONE (1) GALLON OF PRESERVATIVE MIL-PRF-21260E, TYPE PE-10, THROUGH FUEL SYSTEM

ALLOWING EXCESS TO DRAIN INTO CONTAINER.

DO NOT REUSE PRESERVATIVE.

6. REMOVE SUPPLY LINES AND RE-CAP BOTH THE FUEL PUMP INLET AND THE FUEL RETURN LINES.

7. FILL ENGINE CRANK CASE TO OPERATIONAL LEVELS USING A VCI OIL MIXTURE THAT CONSISTS

OF 50% VCI OIL CONFORMING TO MIL-P-46002A AND 50% MANUFACTURER’S RECOMMENDED

ENGINE OIL (SEE PAGE 5).

8. CONNECT STARTER TO 24 VOLT POWER SUPPLY (SEE PAGE 6).

9. REMOVE FLYWHEEL COVER AND FOG APPROXIMATELY 2ml OF A VCI OIL MIXTURE, CONSISTING

OF 50% VCI OIL CONFORMING TO MIL-P-46002A AND 50% MANUFACTURER’S RECOMMENDED

ENGINE OIL, ON THE FLYWHEEL AND RING GEAR TEETH (SEE PAGE 7).

10. REMOVE CAP FROM TURBO CHARGER EXHAUST PORT, FOG WITH 1ml OF A VCI OIL MIXTURE, CONSISTING OF 50% VCI OIL CONFORMING TO MIL-P-46002A AND 50% MANUFACTURER’S

RECOMMENDED ENGINE OIL. (SEE PAGE 6).

11. REMOVE CAP FROM TURBO CHARGER INTAKE PORT, SPRAY OR FOG APPROXIMATELY 12-15 ml OF

A VCI OIL MIXTURE, CONSISTING OF 50% VCI OIL CONFORMING TO MIL-P-46002A AND 50%

MANUFACTURER’S RECOMMENDED ENGINE OIL (SEE PAGE 6).

12. CYCLE THE ENGINE USING THE STARTER UNTIL 36 - 45 ml OF VCI OIL MIXTURE HAS BEEN FOGGED OR SPRAYED INTO THE TURBO CHARGER INTAKE PORT, 12 – 15 ml AT A TIME.

DO NOT CYCLE FOR MORE THAN 5 SECONDS ALLOWING THE STARTER TO REST 30 SECONDS

BETWEEN CYCLES.

13. REMOVE POWER SUPPLY.

14. REPLACE SLAVE FUEL AND OIL FILTERS WITH THE ORIGINAL FILTERS.

15. DRAIN OIL FROM CRANKCASE, REPLACE DRAIN PLUG, TORQUE TO 25LB/FT (SEE PAGE 6).

16. REPLACE ANY REMOVED CAPS AND PLUGS.

17. CAP BREATHER TUBE WITH 3 X 5 POLY BAG SECURE WITH TAPE ASTM-D6123 (SEE PAGE 5).

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 3 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

18. COOLING SYSTEM: IT IS ASSUMED THIS ENGINE, IF NEW, HAS BEEN PREVIOUSLY RUN WITH

COOLANT UTILIZING NON-CHROMATE INHIBITORS BY THE MANUFACTURER. THEREFORE, THE

COOLING SYSTEM PRESERVATION IS NOT REQUIRED.

THIS COMPLETES THE STEPS FOR ENGINE PRESERVATION REQUIRED PRIOR TO PACKAGING.

D. SEAL ALL OPENINGS TO ENGINE INTERIOR WITH CAPS/PLUGS OF APPROPRIATE SIZE.

E. BRACKETS SHALL BE FABRICATED FROM COMMERCIAL GRADE 1/2" THICK PLATE STEEL. BRACKETS SHALL BE FORMED BY BENDING, NOT WELDING AND SHALL BE PAINTED, PLATED OR PRESERVED

USING MIL-PRF-16173, GR 4. SEE PAGES 8 - 10 FOR BRACKET DRAWINGS AND PLACEMENT.

F. ALL HARDWARE SHALL BE COMMERCIAL GRADE AND BE PAINTED, PLATED OR PRESERVED USING

MIL-PRF-16173, GR 4. SEE PAGES 8 & 9 FOR SIZES AND LOCATION.

G. ALL LUMBER SIZES ARE NOMINAL UNLESS OTHERWISE SPECIFIED. SEE PAGES 10 & 11 FOR SIZES

AND ORIENTATION.

H. WRAP ENGINE ENTIRELY IN GREASE PARER, SECURE WITH TAPE ASTM-D6123.

I. APPLY CUSHIONING AROUND THE ENGINE TO PREVENT PUNCTURING THE FOIL ENVELOPE

MATERIAL, SECURE WITH TAPE ASTM-D6123.

J. DESICCANT BAGS SHALL BE PLACED WITHIN FOIL ENVELOPE, BENEATH OIL PAN, BEFORE SEALING

BAG.

K. ENVELOPE FABRICATION SHALL BE IN ACCORDANCE WITH SPECIFICATION MIL-DTL-6060. MATERIAL USED FOR FABRICATION OF GASKETS SHALL CONFORM TO SPECIFICATION ASTM F 104. GASKETS SHALL BE CEMENTED TO EACH SIDE OF THE BAG AT THE MOUNTING LOCATION USING MMM-A-260 ADHESIVE OR COMMERCIAL EQUIVALENT. AFTER POSITIONING BARRIER OVER BOLTS, A SUFFICIENT QUANTITY OF ADHESIVE SHALL BE APPLIED AROUND BOLT AND GASKET TO PROVIDE AN AIRTIGHT

SEAL.

L. CLOSE CONTAINER IN ACCORDANCE WITH CONTAINER SPECIFICATION ASTM-D7478.

M. THE UNIT CONTAINER IS THE SHIPPING CONTAINER.

N. SPECIAL MARKING SHALL BE APPLIED AS FOLLOWS:

1. IN ADDITION TO MIL-STD-129 MARKINGS, THE UNIT CONTAINER SHALL BE MARKED ON THE TOP

AND SIDES WITH MINIMUM 1/2 INCH HIGH BLACK LETTERS "REUSABLE CONTAINER, DO NOT

DESTROY". IN ADDITION, THE TOP AND ENDS SHALL BE MARKED "REMOVE LAG SCREWS TO OPEN

CONTAINER" USING 1/2 INCH HIGH BLACK LETTERS.

2. SECURE WARNING TAG (S) IN A CONSPICUOUS LOCATION ON THE ENGINE TO STATE, “ENGINE OIL

SYSTEM PRESERVED. ENGINE FUEL SYSTEM AND CYLINDERS PRESERVED. BEFORE CRANKING,

REMOVE ALL CAP/PLUGS AND TAPE AND ADD PROPER OPERATIONAL LUBRICANT TO

CRANKCASE”.

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 4 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

ENGINE PRESERVATION SPECIAL EQUIPMENT

FILTERS AND PAIL ARE NOT SHOWN

FUEL FLOW

CHECKING

TOOL

CATERPILLAR

P/N 331-3626

PRESERVATIVE

SUPPLY HOSE

PRESERVATIVE

RETURN HOSE

24 VOLT POWER

SUPPLY

SWITCH TO

ENGAGE AND

DISENGAGE

SOLENOID

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 5 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

ENGINE PRESERVATION LOCATIONS

FUEL FILTER

P/N 26560141

OIL FILTER

P/N 2654403

ENGINE OIL

FILL

BREATHER

TUBE

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 6 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

FUEL

INLET

ENGINE OIL

DRAIN

TURBO INTAKE TURBO EXHAUST

SOLENOID SWITCH INSTALLATION

POSOTIVE TERMINAL

NEGATIVE TERMINAL

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 7 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

FLYWHEEL &

RING GEAR

FUEL

RETURN

LINE

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 8 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012 A

ENVELOPE, ITEM S (FLAT LAYOUT), HOLE LOCATIONS

ALL HOLES PICTURED ON THIS PAGE ARE 1/2” DIAMETER

PACKAGING BILL OF MATERIAL

ITEM SIZE QTY REFERENCE

A 2 X 10 X 57-3/4 2 ASTM-D6199

B 2 X 6 X 24 1 ASTM-D6199

C 9-1/4 X 34 X ½ PLYWOOD 1 ASTM-D6199

D 1 X 10 X 34 1 ASTM-D6199

E 2 X 10 X 34 1 ASTM-D6199

F 4 X 6 X 14 ONE BEVELED EDGE 45° 1 ASTM-D6199

G 4 X 6 X 16 ONE BEVELED EDGE 45° 1 ASTM-D6199

H 8 X 26 GASKET MATERIAL 2 ASTM F 104

I 12 X 36 GASKET MATERIAL 2 ASTM F 104

J 18-3/4 “L” BRACKET 2 SEE DRAWING ON PAGE 12

K 13 “L” BRACKET 2 SEE DRAWING ON PAGE 12

L M12 – 1.75 X 45 MM HARDWARE SET 4

HARDWARE SET CONSISTS OF: 1PC M12 – 1.75 X

45MM HEX BOLT & 1PC M12 LOCK WASHER.

M M16 – 2.00 HARDWARE SET 4

HARDWARE SET CONSISTS OF: 1PC M16 – 2.00 NUT

& 1PC M16 LOCK WASHER.

N M12 – 1.75 X 110MM HARDWARE SET 4

HARDWARE SET CONSISTS OF: 1PC M12 – 1.75 X

90MM HEX BOLT & 1PC M12 LOCK WASHER.

O 1/2 X 1-1/2 STEEL SPACER 4 MCMASTER-CARR P/N 92415A156

P ½ HARDWARE SET 12 HARDWARE SET CONSISTS OF1PC ½” FLAT WASHER

Q 1/2 X 8 HARDWARE SET 2

HARDWARE SET CONSISTS OF: 1PC ½ X 8”

CARRIAGE BOLT, 1PC ½ FLAT WASHER, 1PC ½ LOCK

WASHER & 1PC ½ NUT.

R 1/2 X 12 HARDWARE SET 2

HARDWARE SET CONSISTS OF: 1PC ½ X 12”

CARRIAGE BOLT, 1PC ½ FLAT WASHER, 1PC ½ LOCK

WASHER & 1PC ½ NUT.

S 80 X 132 ENVELOPE (FLAT LAYOUT) 1 MIL-DTL-6060E

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 9 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012 A

“L” BRACKET AND HARDWARE LOCATIONS

HARDWARE

ITEM L

HARDWARE

ITEM M

BRACKET

ITEM K

HARDWARE

ITEM R

HARDWARE

ITEM Q

BRACKET

ITEM J

HARDWARE

ITEM N

BRACKET

ITEM J

SPACER

ITEM O

HARDWARE

ITEM P

(3X PER BOLT)

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 10 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012

BASE HOLE LOCATIONS

BELL HOUSING

ITEM G

ALL HOLES PICTURED ON THIS PAGE

ARE 1/2” DIAMETER

ITEM F

ITEM E

ITEM D

ITEM C

ITEM B

ITEM A

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 11 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012

ITEM A HOLE LOCATIONS

ALL HOLES PICTURED ON THIS PAGE

ARE 1/2” DIAMETER

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 12 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012

ITEM IDENTIFICATION

BRACKET J

QUANTITY: 2

BRACKET K

ITEM I

ITEM S

QUANTITY: 1

ITEM R

ITEM H

ITEM Q

DD FORM 2169, JUN 1997 (EG) PREVIOUS EDITIONS ARE OBSOLETE Page 13 of 13

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CAGE 3. SPI NO.

VK-38244 (72643) ENGINE ASSEMBLY, DIESEL 19207 AK15987019

4. NATIONAL STOCK NO. 5. DATE 6. REVISION

2815-01-598-7019 6/20/2012

BRACKET DIMENSIONS

NOTE: ALL BRACKETS ARE MADE OF 1/2” THICK COMMERCIAL GRADE PLATE STEEL AND FORMED BY

BENDING, NOT WELDED.

BRACKET J

BRACKET K

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