11RGS80 Sow

22 April 2011
Statement of Work
Diesel Fuel Injection Test Equipment
1. Background
1.1. Background. This Statement of Work (SOW) establishes the detailed requirements for test
equipment used to test the diesel fuel injection system components that are present in Marine
Corps ground vehicles and equipment. These diesel fuel injection system components include
injection pumps/injectors (nozzles), Cummins PT pumps/injectors, mechanical/electronic unit
injectors, unit pumps, and common rail pumps/injectors. The requirements within this SOW are
intended to include all of the necessary computerized test equipment and adaptors necessary to
fully test and verify the operational condition of the diesel fuel injection system components. The
test equipment is intended to be installed in existing Marine Corps garrisons or facilities as well
as in a single expandable 20 foot ISO shelter. For a concept of the test equipment installed in the
expandable shelter, see the overhead view concept in Figure 1.
1.2. Appendices. Appendix A lays out the requirements for the fuel injection pump tester.
Appendix B lays out the requirements for the unit injector tester. Appendix C lays out the
requirements for the common rail pump and injector tester. Appendix D lays out the
requirements for the unit Cummins PT pump tester. Appendix E lays out the requirements for the
fuel injector tester. Appendix F contains a list of the vehicles that are required to be tested by
this test equipment and the part numbers of the diesel fuel injection system components items
requiring testing.
Figure 1
Overhead view concept of the test equipment installed in the expandable shelter
DISTRIBUTION STATEMENT A. Approved for public release: distribution is unlimited.
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2. Applicable Documents
2.1. General. The documents listed in this section are specified in sections 3, 4, and the
Appendices 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 documents cited in sections 3, 4, and the Appendices 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 listed in the issue of the Department of
Defense Index of Specifications and Standards (DODISS).
SPECIFICATIONS
FEDERAL
A-A-50271 - Plate, Identification
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-1472 - Department of Defense Design Criteria Standard,
Human Engineering
MIL-STD-1474 - Department of Defense Design Criteria Standard,
Noise Limits
(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are
available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D,
Philadelphia, PA 19111-5094).
FEDERAL
FED-STD-595 - Colors Used in Government Procurement
(The Federal Standard is available from the General Services Administration, Federal Supply
Service Bureau, Specification Section, Suite 8100, 470 East L'Enfant Plaza, SW
Washington, DC 20407.)
2.3. Non-Government publications. The following document(s) form a part of this document to
the extent specified herein. Unless otherwise specified, the issues of the documents that are DoD
adopted are those listed in the issue of the DoDISS cited in the solicitation.
INTERNATIONAL STANDARDS ORGANIZATION
ISO 4008 - Road vehicles – Fuel injection pump testing
ISO 4010 - Diesel engines – Calibrating nozzle, delay pintle
type
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ISO 4093 - Diesel engines – Fuel injection pumps – High-
pressure pipes for testing
ISO 4113 - Road vehicles – Calibration fluid for diesel
injection equipment
ISO 7440 - Road vehicles – Fuel injection equipment testing
ISO 7876 - Fuel injection equipment – Vocabulary
ISO 8984 - Diesel engines – Testing of fuel injectors
ISO 14681 - Diesel engines – Fuel injection pump testing –
Calibrating fuel injectors
ISO/IEC 16022 - Information Technology – International
symbology specification – Data Matrix
(Application for copies should be addressed to the American National Standards Institute, 11 W.
42nd Street, New York, New York 10036.)
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION
NEMA WD6 - Wiring Devices – Dimensional Specification
(Application for copies should be addressed to the National Electrical Manufacturers
Association, 1300 North 17th Street, Rosslyn, Virginia 22209.)
NATIONAL FIRE PROTECTION ASSOCIATION
NFPA 70 - National Electrical Code
2.4. Order of precedence. In the event of a conflict between the text of this document and the
references cited herein, 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. Definitions and disclaimers.
3.1.1. Pictorial representations. The figures included in this SOW represent the government’s
proposed design concept. The controlling requirements are the text requirements of this SOW;
the figures are included only for additional clarity. It is the responsibility of the manufacturer to
ensure that each item offered meets all of the requirements relating to that item.
3.1.2. Alternate design. The pictures and descriptions in this specification should not restrict the
offeror from proposing alternate better (higher quality, faster manufacturability, greater
maintainability, lower cost, or shorter lead time) designs.
3.1.3. Terminology. Terminology related to fuel injection equipment used in this specification is
defined in ISO 7876.
3.1.4. Appendices. The test equipment that is described in Appendix A-E shall meet the
requirements of Section 3.
3.2. Tested diesel fuel injection system components.
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3.2.1. Units under test. All diesel fuel injection system components from the vehicles and
equipment listed in Appendix F require testing. These items shall be the units under test. The test
equipment described in this document shall be able to test all of the units under test listed in
Appendix F to full load and through full confirmation of operation as detailed in the specific
appendix for the test equipment.
3.3. General tester requirements.
3.3.1. Run sheets. Run sheets shall be supplied for each unit under test listed in Appendix F
containing all parameters necessary to fully test and verify the operational condition of the
specific unit under test. The run sheet’s parameters shall define the range for an acceptable unit
under test. The run sheets shall be provided in both paper copies and in electronic file formats
that can be easily edited and revised in Microsoft Office products. For further requirements
surrounding any documentation delivered with the test equipment including copyright release,
see section 3.9.1.1.
3.3.1.1. Responsibility. It is the responsibility of the offeror to obtain the parameters for the run
sheets. The recommended method for obtaining the parameters is to return to the Original
Equipment Manufacturer (OEM). If the OEM is unwilling to provide these technical parameters,
that does not relieve the offeror of the responsibility to provide the information in run sheets for
each unit under test.
3.3.2. User interface. All testers shall be fully computer controlled with an integrated digital
interface or utilize a PC based control system. Testers shall be pre-programmed to test all units
under test listed in Appendix F specific to each tester and have the ability to add tests for new
units under test. The pre-programming shall include all parameters from the run sheets necessary
to fully test and verify the operational condition of the specific unit under test, see section 3.3.1.
The user interface shall display the range of acceptable parameters and the current status of the
parameters. If the test failed, the user interface shall clearly show what parameters caused the
failure and include possible causes for the fault.
3.3.2.1. Software license. The software used in the test equipment shall allow for continuous
operation without license renewal. If the test equipment uses a PC based control system, then the
software shall be able to be installed on a replacement computer with no communication to tech
support or a license server. The software shall allow updates to the test procedures both manually
and from a CD for the addition of new units under test. Critical software update patches
necessary for the continued proper operation of the test equipment shall also be provided without
license renewal; updates to newer software versions with additional features above that typical of
a software patch are not required. Newer software versions shall be provided if they are the only
method for receiving critical software update patches or for continued operation of the test
equipment. All software updates shall be provided on a CD.
3.3.2.2. Single PC based control system. It is anticipated that multiple testers will be used
together to complete a test, with a combination of testers and equipment used for mounting,
driving, measuring, and controlling the units under test. Only one computer shall be required to
complete any single test. It is acceptable to install multiple programs on the single computer to
perform the tests and to switch between the programs during the test, but only a single computer
shall be required to complete the test. Inputs and plugs to the computer from the test equipment
shall not be required to change during the tests.
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3.3.3. Tester computer. In order to assure interchangeability with computers common within the
USMC, testers which include a PC based control system shall utilize a Panasonic Toughbook
model number 30 laptop computer as the primary control of the inputs. The computer shall be
supplied by the contractor. All wireless functions shall be disabled in the BIOS. This computer
shall connect to the tester to run the tests and to view and modify the test reports. If the
Toughbook does not include the necessary inputs or connections to interface with the tester, a
port replicator or similar device shall be used.
3.3.3.1. Computer exchange. This computer shall be able to be exchanged with an equivalent
Toughbook, after programs that include the tests are installed. Exchanging computers, including
installing programs, mounting, and making any connections that are required shall take no longer
than 30 minutes by a single user, unassisted, in the field. No communication to tech support or a
license server shall be required at any time. Any programs that are required to exchange a
computer shall be supplied on a separate CD-ROM or DVD. See Figure 2 for an example of the
tester computer.
Figure 2
Tester computer
3.3.3.2. Output. Tester with PC based control systems shall output a clearly marked test report,
indicating all measured pass/fail parameters and the status of the test. The appearance of the test
report shall be professional, similar to test reports provided from commercially available testers
for other test equipment. For an example of a similar test report from an alternator tester, see
Figure 3. If the test failed, the test report shall clearly show what parameters caused the failure
and include possible causes for the fault. The report shall be in a format that typical Microsoft
Office products can read and open, preferably an excel .xls file. The computer included with the
tester is not required to exhibit Microsoft Office software; however, the computer on the tester
shall exhibit the ability to display the final format of the report. The reports shall be stored on the
computer as files. No printer is required; however, the computer shall be able to write test report
files to a CD to exchange data between computers.
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Figure 3
Example test report
3.3.4. Test connection. The time required to connect any unit under test to any tester shall not
exceed 30 minutes. This time includes any setup and startup times that are required by the tester.
The testers shall be capable of being changed from the typical shut-down condition, not arranged
for any particular item, to ready to begin testing on any item in the units under test list in
Appendix F within 30 minutes.
3.3.4.1. Set up instructions. Instructions regarding the set up of the unit under test as well as the
adapters and connectors required shall be included. An objective would be to include this
information directly in the programming of the tester. A threshold would be to include all
documentation as both paper copies and in file formats that can be easily edited and revised in
Microsoft Office products. For further requirements surrounding any documentation delivered
with the test equipment including copyright release, see section 3.9.1.1.
3.3.4.2. Part numbers and diagrams. The instructions to set up the units under test in the tester
shall include the part numbers of all parts required to connect the items to the tester, both
mechanical and electrical, as well as diagrams of where the parts connect to the tester.
3.3.5. Adaptors. The test equipment shall include all adaptors, mounting hardware, lines,
connectors, plugs, power supplies, electronic interfaces, etc. necessary to properly connect and
test all units under test listed in Appendix F. It is understood that some adaptors may not be
commercially available and will have to be developed.
3.3.5.1. Adapter labeling. All adapters shall be labeled. The labels shall include information
about the adapter, including the adapter’s part number and what units the adapter aids in testing.
The labels on the adapters shall be manufactured to last the economic life of the system and shall
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not interfere with the operation of the tests. Labels shall not separate from the adapters and shall
remain legible and usable. Any proposed methods of labeling the adapters shall be approved
before additional effort is expended to produce the labels. The labels shall be resistant to
degradation from water, oil, grease, and use.
3.3.6. Roll cart. A roll cart shall be included due to the weight of the unit injector tester and
common rail pump and injector testers. The roll cart shall be specifically designed to aid a single
user in the installation and removal of the unit injector tester and common rail pump and injector
testers without having to lift them from the injection pump tester. The roll cart shall also allow
for the easy movement and storage of these testers when not in use. See Figure 4 for an example
of a roll cart that meets these requirements. A known source of the roll cart is the Hartridge
HM1050 Trolley.
Cam box
Common rail
testers
Common rail
control boxes
Roll cart
Figure 4
Roll cart for cam box and common rail testers
3.3.7. Tester mounting. Because the test equipment is intended to be transported and re-located
when mounted within a single expandable 20 foot ISO shelter, all testers shall be sufficiently
durable to survive transport by various methods without damage or recalibration. The offeror
shall provide recommended methods of mounting the testers within the shelter which allow the
testers to survive transports without losing calibration.
3.3.7.1. Shipping brackets. Shipping brackets shall be provided for all testers if necessary to
survive transport. All shipping brackets shall be reusable and shall mount to the testers using
common hand tools. A complete list of tools considered to be common can be made available
upon request.
3.3.8. Expandable shelter. The test equipment is intended to be installed in existing Marine
Corps garrisons or facilities as well as in a single-side expandable 20 foot ISO shelter. Due to the
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limited space available in this shelter, the test equipment shall perform many functions and test
multiple types of units under test. Figure 5 and Figure 6 show an overhead view of the
anticipated layout of the test equipment installed in the shelter in both shop mode (expanded) and
transport mode (not expanded). In the transport mode all of the equipment shall not exceed the
following parameters. The maximum height shall not exceed 77”. The maximum floor space
shall not exceed 60” wide by 166” long. We anticipate all adaptors, cables and connectors not
normally used with the equipment to be stored in a section of drawers with an exterior volume of
81” long x 21” deep x 38” high. The overall weight shall not exceed 25,000 lbs. The offeror shall
demonstrate that the proposed test equipment will not significantly impact the overall layout or
usable workspace of the shelter.
3.3.8.1. Tester maintenance access panel. Full access to the maintenance panels of all testers,
including access for filling and draining fluids, is required when installed in the shelter. If the
maintenance panels are not fully operable due to the mounting location of the tester in the shelter
(that is, the shelter obstructs access to maintenance points), the access panels shall be modified to
allow full access within the constraints of the shelter. An example is if a panel is obstructed from
swinging into the fully open position by the placement of a wall of the shelter, acceptable
modifications would include modifying the access panel on the tester, to allow access from the
interior of the shelter. If access to fully open a panel is obstructed by the ceiling of the shelter,
the panel shall be modified to allow access.
Fuel
Unit injector
injector tester
tester
Fuel
injection
Common pump
rail pump tester
and
injector
tester Cummins
PT pump
Roll cart tester
Approx. 20 Feet
Figure 5
Expandable shelter concept shop mode
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Unit Fuel
injector injector
tester tester
Common Fuel
rail pump injection
and pump
injector tester
tester
Cummins
Roll cart Chiller for testers PT pump
(space claim only, not required) tester
Figure 6
Expandable shelter concept transport mode
3.3.9. Electrical. Testers shall operate off of 120V 1Φ or 208V 3Φ 60 Hz electrical service.
Testers which operate off of 120V 1Φ 60 Hz electrical service shall be rated for and utilize a
power cord with a NEMA 5-15P plug and a length sufficient to plug into an outlet adjacent to the
tester. All other testers shall be able to be hardwired to electrical service using NFPA 70
standards.
3.3.9.1. Higher voltage. Testers which operate off of a higher voltage electrical service of 480V
3Φ 60 Hz will be considered on a case-by-case basis. If accepted, detailed tester electrical
requirements shall be provided necessary to specify a transformer for converting 208V to 480V
3Φ 60 Hz.
3.3.10. Interface with electronics. The connections to power and interface with the electronics of
the units under test, including power supplies, shall meet the specifications to properly and
accurately perform repeatable tests.
3.3.11. Compressed air connection. All testers which require compressed air shall have an easily
accessible threaded connection to attach a quick-connect air connection. If the threaded
connection is not a standard NPT connection, a warning label shall be attached to the connection
stating the type of threads.
3.3.11.1. Compressed air requirement. If testers require compressed air, detailed requirements
shall be provided to aid in the proper sizing and specification of the compressed air system. This
information shall include pressure, volume, and any other special requirements such as filtration,
lubrication, or port size which could affect the design of the compressed air system.
3.3.12. Cooling connections. The test equipment will be deployed to locations without a
sufficient water supply for tester cooling and, if necessary, will be cooled with a closed loop
chiller system. Testers which require water cooling shall also be capable of being cooled with a
typical automotive glycol based antifreeze as coolant when deployed in freezing environments.
3.3.12.1. Cooling requirement. If testers require a water supply for cooling, detailed
requirements shall be provided to aid in the proper sizing and specification of a glycol based
closed loop chiller system. This information shall include energy dissipation, water (coolant)
flow, minimum/maximum acceptable coolant temperature, coolant connection size/type, and any
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other special requirements which could affect the design of the chiller system.
3.3.13. Calibration fluid. All testers shall be able to perform tests on the units under test with
calibration fluid compliant with ISO 4113. Calibration fluid is required for the verifications and
demonstrations for the acceptance of the first unit. A known source for calibration fluid is Viscor
1487 available from the Rock Valley Oil and Chemical Co. in Rockford, IL.
3.3.14. Filters. Each tester shall be supplied with one additional complete new set of every filter
included in the tester for replacement. This includes any air filters, oil filters, and test fluid
filters.
3.3.14.1. Filters for test. After the verifications and demonstrations for the acceptance of the first
units, all the filters in the testers shall be changed so that when they are delivered, the testers
have unused filters. This requirement is in addition to the complete set of every filter included in
the testers for replacement as required in section 3.3.14.
3.3.15. Supplies. Consumable supplies such as calibration fluid, spill kits, safety equipment
(hearing protection, eye protection, eye wash station, etc.), or other consumable items shall not
be included in the test equipment. These supplies will be furnished by the using unit and safety
officer. However, all consumable supplies required to complete the verifications and
demonstrations for the acceptance of the first unit will be the responsibility of the contractor, see
section 4. Note that these materials are only required for the demonstrations and are not required
to be provided with the delivery of the unit. For more information on safety requirements, see
section 3.5. Any safety hazards that would occur during the demonstrations are the contractor’s
responsibility. All safety materials required during the demonstrations shall be provided by the
contractor.
3.4. General requirements. The following requirements apply to the test equipment and all
individual items therein.
3.4.1. Hardware. All metal hardware shall consist entirely of 316 Stainless Steel. Other materials
for hardware items not commercially available in 316 Stainless Steel will be considered on a
case-by-case basis.
3.4.2. Corrosion prevention. The test equipment will be deployed in locations adjacent to salt
water and will operate in salt spray environments. In order to better withstand the corrosive
environments expected when deployed, all electrical connections, circuit cards and other
electronic components that are part of the test equipment shall have a conformal coating applied
for corrosion prevention. For an example of components from an alternator tester that did not
have corrosion prevention, see Figure 7.
3.4.2.1. Acrylic conformal coating. The preferred corrosion prevention used on the test
equipment is an acrylic conformal coating due to the ease of repair from an aerosol can and the
ability to dry at room temperature within a reasonable amount of time. Conformal coatings other
than Acrylic shall be approved on a case-by-case basis.
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Figure 7
Alternator tester corrosion problems
3.4.3. Finish. The exterior surface finish shall be clean and clear from visible imperfections. The
finish shall exhibit corrosion resistance, and shall have no sharp edges or projections.
3.5. Safety requirements.
3.5.1. Safety. The test equipment shall not present any uncontrolled safety or health hazards
throughout the life cycle of the system.
3.5.2. Physical hazard control. Mechanical guards, electrical insulation, thermal insulation, and
other safety devices shall be provided to protect operators and maintenance personnel from
inadvertent contact with electrically energized parts, high temperature surfaces, and other
physical hazards. The safety devices shall not interfere with the operation of the test equipment.
Exposed sharp corners and sharp edges shall be eliminated if they serve no functional purpose.
Hazards that cannot be eliminated, cannot be controlled by equipment placement, and cannot be
controlled by protective devices shall be identified to the user by printed warnings or cautions.
Product safety signs and labels shall conform to ANSI Z535.4.
3.5.3. Toxic materials. The test equipment shall be constructed of materials that, in their cured,
dried, or other final processed state, do not present a health hazard to personnel during
transportation, operation, or maintenance. Exposure to temperatures of 160º F for extended
periods shall not result in accumulation of toxic vapors that exceed the National Institute of
Safety and Health (NIOSH) Threshold Limit Values for the substances present.
3.6. Human engineering requirements.
3.6.1. Human interface. The test equipment shall be suitable for setup, operation, and
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maintenance by the majority of U.S. Marine Corps personnel, from the fifth percentile female to
the ninety-fifth percentile male. Basic U.S. Marine Corps anthropometric charts and applicable
DoD human engineering guidelines can be found in MIL-HDBK-759.
3.6.2. Access and operation. The test equipment shall comply with the human engineering
directives outlined in MIL-STD-1472.
3.7. Environment requirements.
3.7.1. Ozone. All gaskets, electric cable covers and other elastomer parts exposed to air shall be
ozone resistant.
3.7.2. Ozone depleting substances. All materials shall be free of ozone depleting substances per
applicable Federal regulations in effect on the date of manufacture.
3.7.3. Fungus and moisture. The test equipment electrical circuits and other integral parts shall
be composed of inherently fungus and moisture resistant materials, or shall be protected from
fungus and moisture damage by protective coating(s) or hermetic seal(s). All gaskets, electric
cable covers and other elastomer parts that are exposed to air shall be fungus resistant.
3.8. Ease of maintenance.
3.8.1. Access. It shall be possible for the target population to perform preventative maintenance
on the test equipment.
3.8.2. Latches. All latches utilized shall be properly adjusted before the test equipment is offered
for acceptance by the Government.
3.8.3. Fastening devices. Screws, pins, bolts, and similar parts shall be installed with means for
preventing loss of tightness. The methods for preventing loss of tightness shall be according to
accepted engineering standards and practices. No such parts subject to removal or adjustment
shall be swaged, staked, or otherwise deformed.
3.9. Technical information.
3.9.1. Technical manuals. All test equipment shall be supplied with technical manuals written in
accordance with the contractor’s standard practice. These manuals shall include operations and
maintenance manuals for all testers. The manuals shall be supplied in both electronic Adobe PDF
and printed formats. Scans of printed pages shall not be acceptable for the electronic Adobe PDF
format; the text shall be electronically searchable.
3.9.1.1. Copyright release. Any manuals or documentation supplied with the test equipment shall
include a copyright release that allows the government to reprint and distribute the manuals
through a variety of methods. These methods shall include on-line distribution, specifically
through the Marine Corps Technical publications website. Each manual’s front page shall
specifically state the copyright release and allowance for redistribution and reprinting.
4. Verification / Demonstration.
4.1. General provisions. The verifications / demonstrations herein shall be performed to
demonstrate that the item conforms to portions of sections 3, and Appendix A-F of this
specification.
4.2. Demonstration conditions. Unless otherwise specified, the contractor shall perform all
demonstrations in accordance with the conditions specified herein. The demonstrations are
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related to the requirements as shown in Table 1 The demonstrations are to be performed at the
contractor’s expense at a location of the contractor’s choice within the United States.
4.3. Rejection. If any assembly, specimen or component fails to comply with any of the
applicable requirements; the sample shall be rejected. The Government reserves the right to
terminate demonstration upon any failure of an assembly or component during the
demonstration.
4.4. Preparation. The contractor shall prepare the test equipment for demonstration by
performing any normal service, lubrication, and adjustment as described within the operator’s
technical manual. If preparations for operation are required that are not detailed in the manual,
the manual is not acceptable, and shall be updated before acceptance.
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Table 1
Verification / Demonstration Matrix
Diesel Fuel Injection Verification /
Requirement
Test Equipment Demonstration
Fuel injection pump tester Appendix A 4.5.1
Unit injector tester Appendix B 4.5.2
Common rail pump and injector
Appendix C 4.5.3
testers
Common rail pump tester C3.1.1, C3.1.1.1, C3.1.1.2 4.5.3.1
Common rail injector tester C3.1.2, C3.1.2.1, C3.1.2.2 4.5.3.2
Cummins PT pump tester Appendix D 4.5.4
Fuel injector tester Appendix E 4.5.5
Run sheets 3.3.1, 3.3.1.1 4.5.6
User interface 3.3.2, 3.3.2.1, 3.3.2.2 4.5.7
Tester computer 3.3.3, 3.3.3.1 4.5.8
Test connection 3.3.3.2, 3.3.4.1, 3.3.4.2 4.5.9
Adaptors 3.3.5, 3.3.5.1 4.5.10
Roll cart 3.3.6 4.5.11
Tester mounting 3.3.7, 3.3.7.1 4.5.12
Expandable shelter 3.3.8, 3.3.8.1 4.5.13
Electrical 3.3.9, 3.3.9.1 4.5.14
Compressed air connection 3.3.11, 3.3.11.1 4.5.15
Cooling connections 3.3.12, 3.3.12.1 4.5.16
Calibration fluid 3.3.13 4.5.17
Filters 3.3.14 4.5.18
Hardware 3.4.1 4.5.19
Corrosion prevention 3.4.2, 3.4.2.1 4.5.20
Finish 3.4.3 4.5.21
Technical information 3.9.1, 3.9.1.1 4.5.22
Units under test Appendix F 4.5.23
4.5. Test equipment verifications.

4.5.1. Fuel injection pump tester. Examine the fuel injection pump tester. Verify that the tester,
calibrating injectors, and high pressure pipes are able to test and are in accordance with
applicable ISO standards. Confirm that the tester has a drive motor of at least 20 hp and
electronic volume measurement for pumps up to 12 cylinders. Verify that the tester has a method
for accurately controlling the temperature of the calibration fluid used in the testes.
4.5.2. Unit injector tester. Examine the unit injector tester. Verify that the tester is able to
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measure the required parameters including at least revolutions per minute (RPM) of the cam, fuel
volume delivery, supply pressure, injection timing, solenoid coil resistance, and solenoid timing.
Confirm that application specific cams are used that test to the proper stroke to simulating engine
conditions. Confirm that the tester is able to be mounted, driven, measured, and controlled by the
fuel injection pump tester.
4.5.3. Common rail pump and injector testers. Examine the common rail pump and injector
testers. Confirm that the testers include a safety enclosure rated for at least 29,000 psi with an
interlock which prevents testing if the enclosure is not properly secured or latched. Verify that a
pressure relief valve is present which will immediately and safely discharge the high pressure
and stop the common rail pump if the safety enclosure is opened. Confirm that the testers have a
filter with at least a 2 micron rating for filtering the calibration fluid used in the testers and have
a pressure control valve to prevent damage between the connections to the measuring unit.
4.5.3.1. Common rail pump tester. Examine the common rail pump tester. Verify that the tester is
able to measure the required parameters including at least the pump flow over its full operating
range and the resistance of the solenoids of the pump. Confirm that the tester is able to
independently control the open loop current of up to two pump solenoids simultaneously and
adjust the supply voltage and pulse width modulation frequency to drive the solenoids of the
pump.
4.5.3.2. Common rail injector tester. Examine the common rail injector tester. Verify that the
tester is able to measure the required parameters including at least the injector coil resistance,
response time, and delivery. Confirm that the tester includes an injector fixture assembly which
enables the safe and repeatable testing of up to 4 injectors simultaneously and that the tester is
able to control the rail pressure as well as the injector current, voltage, and pulse width
modulation frequency.
4.5.4. Cummins PT pump tester. Examine the Cummins PT pump tester. Verify that the tester is
able to measure the required parameters including at least the gear pump suction and pressure;
manifold pressure; primary flow; secondary flow for checking throttle leakage; and fluid
temperature. Confirm that the tester includes casters which allow the tester to be easily moved
out of the way when not in use as well as a calibration fluid reservoir with sufficient capacity to
run the tests and features at least a drain, secure lid, calibration fluid filter, and a temperature
control system which is able to heat and cool the calibration fluid. Verify that the tester is able to
be mounted and driven by the fuel injection pump tester.
4.5.5. Fuel injector tester. Examine the fuel injector tester. Verify that the tester conforms and is
able to test in accordance with ISO 8984, has a powered automated pumping action, and does not
feature a hand-lever-operated pumping action. Verify that the tester is able to measure the
required parameters including at least nozzle opening pressure, chatter (atomization), spray
pattern, seat leakage, and back-leakage tests as described in ISO 8984. Confirm that the tester
has electronic pressure and volume measuring; is able to control all of the electronics of the
Appendix F units under test necessary to verify their operational condition; and has a lighted
spray chamber and extracts the fumes generated during the tests.
4.5.6. Run sheets. Confirm that run sheets are supplied for each unit under test in both paper
copies and in electronic file formats that can be easily edited and revised in Microsoft Office
products. Verify that the run sheets contain all parameters necessary to fully test and verify the
operational condition of the specific unit under test and define the range for an acceptable unit
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under test.
4.5.7. User interface. Confirm that all testers are fully computer controlled with an integrated
digital interface or utilize a PC based control system. Verify that the testers are pre-programmed
to test all units under test specific to each tester and have the ability to add tests for new units
under test. Confirm that testers which are used together utilize only one PC based control system.
4.5.8. Tester computer. Confirm that testers with a PC based control system utilize a Panasonic
Toughbook model number 30 laptop computer as the primary control of the inputs of the tester.
Exchange the tester computer with an equivalent Toughbook and verify that the exchange takes
no longer than 30 minutes, including installing all necessary hardware, by a single user with no
communication to tech support or a license server.
4.5.9. Test connection. Verify that the time required to connect any unit under test to any tester
does not exceed 30 minutes including any setup and startup times that are required by the tester
and with the tester in a typical shut-down condition. Confirm that the instructions for how to set
up the unit under test include the part numbers of all parts required to connect the items to the
tester, both mechanical and electrical, as well as diagrams of where the parts are supposed to
connect to the tester.
4.5.10. Adaptors. Confirm that the test equipment includes all adaptors, mounting hardware,
lines, connectors, plugs, power supplies, electronic interfaces, etc. necessary to properly connect
and test all units under test. Verify that the labels on the adaptors including the adapter’s part
number and what units the adapter aids in testing.
4.5.11. Roll cart. Have a single user install and remove the unit injector tester and the common
rail pump and injector testers from the roll cart to the fuel injection pump tester. Confirm that
this operation did not require lifting the testers. Verify that the roll cart also allows for the easy
movement and storage of these testers when not in use.
4.5.12. Tester mounting. Confirm that recommended methods of mounting the testers within the
shelter are provided which allow the testers to survive multiple transports without losing
calibration. If necessary to survive transport, verify that shipping brackets are provided for all
testers which are reusable and mount to the testers using common hand tools.
4.5.13. Expandable shelter. Verify that the test equipment will not significantly impact the
overall layout or usable workspace of the shelter. Confirm that the maintenance panels of all
testers, including access for filling and draining fluids allow or have been modified to allow full
access when installed in the shelter.
4.5.14. Electrical. Confirm that the testers operate off of 120V 1Φ or 208V 3Φ 60 Hz electrical
service. Confirm that either a NEMA 5-15P is utilized or that the testers are able to be hardwired
to electrical service using NFPA 70 standards. If 480V 3Φ 60 Hz is approved for use with a
tester, verify that detailed tester electrical requirements are provided necessary to specify a
transformer for converting 208V to 480V 3Φ 60 Hz.
4.5.15. Compressed air connection. Verify that testers which require compressed air have an
easily accessible threaded connection to attach a quick-connect air connection. If the threaded
connection is not a standard NPT connection, confirm that a warning label is attached to the
connection stating the type of threads. Verify that detailed requirements are provided to aid in the
proper sizing and specification of the compressed air system.
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4.5.16. Cooling connections. If a tester requires water cooling, verify that the tester is capable of
being cooled with typical automotive glycol based antifreeze as coolant. Verify that detailed
requirements are provided to aid in the proper sizing and specification of a glycol based closed
loop chiller system including energy dissipation, water (coolant) flow, minimum/maximum
acceptable coolant temperature, coolant connection size/type, and any other special requirements
which could affect the design of the chiller system.
4.5.17. Calibration fluid. Confirm that all testers are able to perform tests on the units under test
with calibration fluid compliant with ISO 4113.
4.5.18. Filters. Confirm that all the filters in the testers are replaced after the verifications and
demonstrations are complete so that when they are delivered, the testers have unused filters. In
addition to replacing the filters, verify that each tester is supplied with one additional complete
new set of every filter included in the tester for replacement.
4.5.19. Hardware. Verify that all metal hardware consists entirely of 316 Stainless Steel.
4.5.20. Corrosion prevention. Verify that all electrical connections, circuit cards and other
electronic components that are part of the test equipment have a conformal coating applied for
corrosion prevention.
4.5.21. Finish. Confirm that all exterior surface finishes are clean and clear from visible
imperfections, exhibit corrosion resistance, and have no sharp edges or projections.
4.5.22. Technical information. Verify that all test equipment is supplied with technical manuals
written in accordance with the contractor’s standard practice including operations and
maintenance manuals for all testers. Confirm that the manuals are supplied in both electronic
Adobe PDF and printed formats. Confirm that the text of the electronic Adobe PDF format
technical manuals is electronically searchable and that scans of printed pages are not included.
4.5.23. Units under test. Confirm that each of the units under test listed in Appendix F is
supplied. Test each unit under test on all required testers. Confirm that all of the adapters and
connectors are supplied to allow testing of each unit under test. Confirm that the operational
condition of each unit under test is fully tested and verified to full load.
5. Packaging.
5.1. Packaging. Preservation, packaging, packing, unitization and marking furnished by the
supplier shall provide protection for a minimum of one year, provide for multiple handling,
redistribution and shipment by any mode and meet or exceed the following requirements.
5.1.1. Cleanliness. Items shall be free of dirt and other contaminants which would contribute to
the deterioration of the item or which would require cleaning by the customer prior to use.
Coatings and preservatives applied to the item for protection are not considered contaminants.
5.1.2. Preservation. Items susceptible to corrosion or deterioration shall be provided protection
by means of preservative coatings, volatile corrosion inhibitors, desiccants, waterproof and/or
water/vaporproof barriers.
5.2. Unit package. A unit package shall be so designed and constructed that it will contain the
contents with no damage to the item(s), and with minimal damage to the unit pack during
shipment and storage in the shipping container, and will allow subsequent handling. The
outermost component of a unit package shall be a container such as a sealed bag, carton or box.
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5.3. Unit package quantity. Unless otherwise specified, the unit package quantity shall be one
each part, set, assembly, kit, etc.
5.4. Intermediate package. Intermediate packaging is required whenever one or more of the
following conditions exists:
a. the quantity is over one (1) gross of the same national stock number,
b. use enhances handling and inventorying,
c. the exterior surfaces of the unit pack is a bag of any type, regardless of size,
d. the unit pack is less than 64 cubic inches,
e. the weight of the unit pack is under five (5) pounds and no dimension is over twelve
(12) inches.
Intermediate containers shall be limited to a maximum of 100 unit packs, a net load of 40
pounds, or a maximum volume of 1.5 cubic feet, whichever occurs first.
5.5. Packing.
5.5.1. Shipping containers. Unit packages and intermediate packages not meeting the
requirements for a shipping container shall be packed in shipping containers. All shipping
containers shall be the most cost effective and shall be of minimum cube to contain and protect
the items.
5.5.2. Shipping containers. The shipping containers (including any necessary blocking, bracing,
cushioning, or waterproofing) shall comply with the regulations of the carrier used and shall
provide safe delivery to the destination. The shipping packaging shall be capable of multiple
handling and storage under most conditions (such as stacked storage and exterior storage) for a
minimum of one year.
5.6. Unitization. Shipments shall be palletized if they have a total cubic displacement of 50 cubic
feet or more unless skids or other forklift handling features are included on the containers. Pallet
loads must be stable, and to the greatest extent possible, provide a level top for ease of stacking.
The weight capacity of the pallet must be adequate for the load. The preferred commercial
expendable pallet is a 40 inch x 48 inch, 4-way entry pallet although variations may be permitted
as dictated by the characteristics of the items being unitized. The load shall be contained in a
manner that will permit safe handling during shipment and storage.
5.7. Marking. Each shipping container shall be marked in accordance with MIL-STD-129,
including bar coding. The contractor is responsible for application of special markings as
discussed in the Military Standard regardless of whether specified in the contract or not. Special
markings include, but are not limited to, Shelf-life markings, structural markings, and
transportation special handling markings. The marking of pilferable and sensitive materiel will
not identify the nature of the materiel.
5.7.1. Identification and address. Contractors and vendors shall apply identification and address
markings with bar codes in accordance with this standard. For shipments moving to overseas
locations and for mobile deployable units, the in-the-clear address must also include the host
country geographic address and the APO/FPO address. The MSL will include both linear and 2D
bar codes per the standard. The DD Form 250 or the commercial packing list shall have bar
coding applied as per Direct Vendor Delivery Shipments in the standard (except for deliveries to
DLA Distribution Depots, e.g. New Cumberland, San Joaquin, Red River, Anniston). Packing
lists are required in accordance with the standard, see paragraph 5.3.
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5.7.2. Military shipping label. Commercial software may be used to generate a Military
Shipment Label / Issue Receipt Document (MSL/IRRD) including the required Code 39 and 2D
(PDF417) bar codes. However, the commercial software must produce labels/documents which
comply with the requirements of MIL-STD-129. Contractors shall insure that the "ship to" and
"mark for" in-the-clear delivery address is complete including: consignee's name, organization,
department name, office, building, room, street address, city, state, country code, & DODAAC.
5.7.3. Heat treatment and marking of wood packaging materials. All non-manufactured wood
used in packaging shall be heat treated to a core temperature of 56 degrees Celsius for a
minimum of 30 minutes. The box/pallet manufacturer and the manufacturer of wood used as
inner packaging shall be affiliated with an inspection agency accredited by the board of review
of the American Lumber Standard Committee. The box/pallet manufacturer and the
manufacturer of wood used as inner packaging shall ensure traceability to the original source of
heat treatment. Each box/pallet shall be marked to show the conformance to the International
Plant Protection Convention Standard. Boxes/pallets and any wood used as inner packaging
made of non-manufactured wood shall be heat-treated. The quality mark shall be placed on both
ends of the outer packaging, between the end cleats or end battens; on two sides of the pallet.
Foreign manufacturers shall have the heat treatment of non-manufactured wood products verified
in accordance with their National Plant Protection Organization’s compliance program.
5.7.4. Additional marking. The exterior of each unit pack shall contain the following
information, on a separate label from the shipping label.
a. Nomenclature: DIESEL FUEL INJECTION TEST EQUIPMENT
b. Manufacturer: (To be identified)
c. Manufacturer’s CAGE Code: (To be identified)
d. Contract Number: (To be identified)
e. Attn: Peggi Blakley 812-854-2086
5.8. Quality assurance. The contractor is responsible for establishing a quality system. Full
consideration to examinations, inspections, and tests will be given to ensure the acceptability of
the commercial package.
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Appendix A:
Fuel Injection Pump Tester
A1. Background.
A1.1 Background. This appendix establishes the detailed requirements for test equipment used to
test the diesel fuel injection pumps that are present in Marine Corps ground vehicles and
equipment. The requirements are intended to include all of the necessary computerized test
equipment and adaptors necessary to fully test and verify the operational condition of these diesel
fuel injection pumps. This test equipment, along with the other test equipment described in this
document, is intended to be installed in existing Marine Corps garrisons or facilities as well as in a
single-side expandable 20 foot ISO shelter. See Figure A1 for an example of a fuel injection pump
tester.
A1.2 Units under test. Appendix F contains a list of the vehicles and equipment and their
associated units under test that are required to be verified by this test equipment.
Figure A1
Fuel injection pump tester
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A2. Applicable Documents
A2.1 See Section 2.
A3. Requirements
A3.1 Test equipment.
A3.1.1 Tester. The fuel injection pump tester shall fully test and verify the operational condition of
all diesel fuel injection pumps listed in the units under test list in Appendix A. The tester shall be
supplied with the appropriate adaptors, fixtures, connectors, and test injectors. See Figure A1 for a
representation of a fuel injection pump tester.
A3.1.2 Standards. The fuel injection pump tester shall be able to test in accordance with ISO 4008
Road vehicles – Fuel injection pump testing. The calibrating injectors and nozzles used on the
injection pump tester shall be able to test in accordance with ISO 4010 Diesel engines –
Calibrating nozzle, delay pintle type, ISO 7440 Road vehicles – Fuel injection equipment testing,
and ISO 14681 Diesel engines – Fuel injection pump testing – Calibrating fuel injectors. The high
pressure pipes used on the fuel injection pump tester shall be able to test in accordance with ISO
4093 Diesel engines – Fuel injection pumps – High-pressure pipes for testing.
A3.1.2.1 Test report. The results of the test shall be clearly marked on the test report, indicating
all measured pass/fail parameters and the status of the test. See 3.3.3.2 for more information on
the test report.
A3.1.3 Specifications. The fuel injection pump tester shall have a 20 hp minimum drive motor and
electronic volume measurement for pumps up to 12 cylinders. Testers with manual analog volume
measuring glasses shall not be accepted.
A3.1.3.1 Temperature control. The fuel injection pump tester shall have a method for accurately
controlling the temperature of the calibration fluid used in the testes. Heating the calibration fluid
is expected to utilize electric resistive heating. See 3.3.12 for more information on the
requirements of the cooling connection.
A3.2 General tester requirements.
A3.2.1 See section 3.
A4. Verification / Demonstration.
A4.1 See Section 4.
A5. Packaging.
A5.1 See Section 5.
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Appendix B:
Unit Injector Tester
B1. Background
B1.1. Background. This appendix establishes the detailed requirements for test equipment used
to test the electronic unit injectors, mechanical unit injectors, Cummins PT injectors, and unit
pumps that are present in Marine Corps ground vehicles and equipment. The requirements are
intended to include all of the necessary computerized test equipment and adaptors necessary to
fully test and verify the operational condition of these diesel fuel injection components. This test
equipment, along with the other test equipment described in this document, is intended to be
installed in existing Marine Corps garrisons or facilities as well as in a single-side expandable 20
foot ISO shelter. See Figure B1 for an example of a unit injector tester.
B1.2. Units under test. Appendix F contains a list of the vehicles and equipment and their
Figure B1
Unit injector tester
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B2. Applicable Documents
B2.1. See Section 2.
B3. Requirements
B3.1. Test equipment.
B3.1.1. Tester. The unit injector tester shall fully test and verify the operational condition of all
electronic unit injectors, mechanical unit injectors, Cummins PT injectors, and unit pumps listed
in the units under test list in Appendix F. These shall be the Appendix B units under test. The
tester shall be supplied with the appropriate adaptors, fixtures, and connectors. See Figure B1
and Figure A1 for a representation of testers for the Appendix B units under test.
B3.1.2. Test parameters. To fully test and verify the operational condition of the Appendix B
units under test, the tester shall measure multiple parameters while simulating engine conditions.
These parameters shall include at least revolutions per minute (RPM) of the cam, fuel volume
delivery, supply pressure, and injection timing. Solenoid operation, including coil resistance and
timing, shall also be measured for electronic unit injectors. Other parameters required to fully
test and verify the operational condition of a specific Appendix B unit under test shall be
measured.
B3.1.2.1. Test report. The results of the test shall be clearly marked on the test report, indicating
all measured pass/fail parameters from B3.1.2 and the status of the test. See 3.3.3.2 for more
information on the test report.
B3.1.3. Specifications. To simulate engine conditions, the tester shall consist of a cam assembly
which is controlled, measured, driven, and mounts to the injection pump tester described in
Appendix A. The cams used in the tester shall match the application profiles of the Appendix B
units under test to guarantee they are tested to the proper stroke.
B3.1.4. Fuel injection pump tester. The unit injector tester shall be mounted, driven, measured,
and controlled by the fuel injection pump tester described in Appendix A. See sections 3.3.2 and
3.3.3 for more information on the requirements for the controlling computer and software of the
testers.
B3.2. General tester requirements.
B3.2.1. See section 3.
B4. Verification / Demonstration.
B5. Packaging.
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Appendix C:
Common Rail Pump and Injector Tester
C1. Background.
C1.1. Background. This appendix establishes the detailed requirements for test equipment used to
test the common rail pumps and injectors that are present in Marine Corps ground vehicles and
equipment. The requirements are intended to include all of the necessary computerized test
equipment and adaptors necessary to fully test and verify the operational condition of these
common rail pumps and injectors. This test equipment, along with the other test equipment
described in this document, is intended to be installed in existing Marine Corps garrisons or
facilities as well as in a single-side expandable 20 foot ISO shelter. See Figure C1 for an example
of testers for common rail pumps and injectors.
C1.2. Units under test. Appendix F contains a list of the vehicles and equipment and their
Figure C1
Common rail pump and injector testers
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C2. Applicable Documents.
C2.1. See Section 2.
C3. Requirements
C3.1. Test equipment.
C3.1.1. Common rail pump tester. The common rail pump tester shall fully test and verify the
operational condition of all common rail pumps listed in Appendix F. The tester shall be supplied
with the appropriate adaptors, fixtures, and connectors. See Figure C2, Figure C4, and Figure A1
for a representation of testers for common rail pumps.
C3.1.1.1. Test parameters. To fully test and verify the operational condition of the common rail
pumps, the tester shall measure multiple parameters. These parameters shall include at least the
pump flow over its full operating range as well as the resistance of the solenoids of the pump.
Other parameters required to fully test and verify the operational condition of a specific common
rail pump shall be measured.
C3.1.1.1.1 Test report. The results of the test shall be clearly marked on the test report, indicating
all measured pass/fail parameters from C3.1.1.1 and the status of the test. See 3.3.3.2 for more
C3.1.1.2. Specifications. In addition to the measured test parameters, the tester shall also be able
to independently control the open loop current of up to two pump solenoids simultaneously and
adjust the supply voltage and pulse width modulation frequency to drive the solenoids of the
pump.
Figure C2
Common rail pump test control system
C3.1.2. Common rail injector tester. The common rail injector tester shall fully test and verify
the operational condition of all common rail injectors listed in Appendix F. The tester shall be
supplied with the appropriate adaptors, fixtures, and connectors. See Figure C3, Figure C4, and
Figure A1 for a representation of testers for common rail injectors.
C3.1.2.1. Test parameters. To fully test and verify the operational condition of the common rail
injectors, the tester shall measure multiple parameters. These parameters shall include at least the
injector coil resistance, response time, and delivery. Other parameters required to fully test and
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verify the operational condition of a specific common rail pump shall be measured.
C3.1.2.1.1 Test report. The results of the test shall be clearly marked on the test report, indicating
all measured pass/fail parameters from C3.1.2.1 and the status of the test. See 3.3.3.2 for more
C3.1.2.2. Specifications. The tester shall include an injector fixture assembly which enables the
safe and repeatable testing of up to 4 injectors simultaneously. In addition to the measured test
parameters, the tester shall also be able to control the rail pressure as well as the injector current,
voltage, and pulse width modulation frequency.
Figure C3
Common rail injector test control system
C3.1.3. Safety enclosure. Due to extremely high operating pressures, the testers for common rail
pumps and injectors shall include a safety enclosure rated for at least 29,000 psi with an interlock
which prevents testing if the enclosure is not properly secured or latched. A pressure relief valve
shall immediately and safely discharge the high pressure and stop the common rail pump if the
safety enclosure is opened.
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Figure C4
Common rail base kit
C3.1.4. Additional requirements. The testers shall have a filter with at least a 2 micron rating for
filtering the calibration fluid used in the testers. The tester shall also have a pressure control
valve to prevent damage between the connections to the measuring unit.
C3.1.5. Fuel injection pump tester. It is anticipated that the common rail pump and injector
testers will be driven and controlled by the fuel injection pump tester described in Appendix A.
See sections 3.3.2 and 3.3.3 for more information on the requirements for the controlling
computer and software of the testers.
C3.2. General tester requirements.
C3.2.1. See section 3.
C4. Verification / Demonstration.
C5. Packaging.
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Appendix D:
Cummins PT Pump Tester
D1. Background.
D1.1. Background. This appendix establishes the detailed requirements for test equipment used to
test the Cummins PT pumps that are present in Marine Corps ground vehicles and equipment. The
requirements are intended to include all of the necessary computerized test equipment and adaptors
necessary to fully test and verify the operational condition of these Cummins PT pumps. This test
equipment, along with the other test equipment described in this document, is intended to be
installed in existing Marine Corps garrisons or facilities as well as in a single-side expandable 20
foot ISO shelter. See Figure A1 for an example of a Cummins PT pump tester.
D1.2. Units under test. Appendix F contains a list of the vehicles and equipment and their
Figure D1
Tester for Cummins PT pumps
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D2. Applicable Documents.
D2.1. See Section 2.
D3. Test equipment.
D3.1. Cummins PT pump tester. The Cummins PT pump tester shall fully test and verify the
operational condition of all Cummins PT pumps listed in Appendix F. The tester shall be
supplied with the appropriate adaptors, fixtures, and connectors. See Figure D1 and Figure A1
for a representation of testers for Cummins PT pumps.
D3.1.1. Test parameters. To fully test and verify the operational condition of the Cummins PT
pumps, the tester shall measure multiple parameters. These parameters shall include at least the
gear pump suction and pressure; manifold pressure; primary flow; secondary flow for checking
throttle leakage; and fluid temperature. Other parameters required to fully test and verify the
operational condition of a specific Cummins PT pump shall be measured.
D3.1.2. Specifications. The tested and measured parameters of the Cummins PT pump tester are
not required to be computer controlled; however, the method of driving of the pump shall follow
the user interface requirements, see 3.3.2. Casters shall also be included which allow the tester to
be easily moved out of the way when not in use.
D3.1.2.1. Calibration fluid. The tester shall also feature a calibration fluid reservoir with
sufficient capacity to run the tests. The reservoir shall feature a drain, secure lid, calibration fluid
filter, and a temperature control system which is able to heat and cool the calibration fluid. If the
calibration fluid cooling system requires a supply of water, it shall be able to adapt to the cooling
system for the fuel injection pump tester described in Appendix A.
D3.1.3. Fuel injection pump tester. The Cummins PT pump tester shall be used in conjunction
with the fuel injection pump tester described in Appendix A, allowing the tested pump to be
mounted and driven by the fuel injection pump tester described in Appendix A and the
verification of operational condition to be performed on the Cummins PT pump tester.
D3.2. General tester requirements.
D3.2.1. See section 3.
D4. Verification / Demonstration.
D5. Packaging.
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Appendix E:
Fuel Injector Tester
E1. Background.
E1.1. Background. This appendix establishes the detailed requirements for test equipment used
to test the diesel fuel injectors, unit injectors, common rail injectors, and nozzles that are present
in Marine Corps ground vehicles and equipment. The requirements are intended to include all of
the necessary computerized test equipment and adaptors necessary to test and verify the
operational condition of these diesel fuel injection components. This test equipment, along with
the other test equipment described in this document, is intended to be installed in existing Marine
Corps garrisons or facilities as well as in a single-side expandable 20 foot ISO shelter. See
Figure E1 for an example of a fuel injector tester.
E1.2. Units under test. Appendix F contains a list of the vehicles and equipment and their
Figure E1
Diesel fuel injector tester
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E2. Applicable Documents
E2.1. See Section 2.
E3. Requirements
E3.1. Test equipment.
E3.1.1. Tester. The fuel injector tester shall test and verify the operational condition of all diesel
fuel injectors, unit injectors, common rail injectors, and nozzles listed in the units under test list
in Appendix F. These shall be the Appendix F units under test. The tester shall be supplied with
the appropriate adaptors, fixtures, connectors, and electronic signal units. See Figure E1 for a
representation of testers for the Appendix E units under test.
E3.1.2. Standards. The tester shall conform to and be able to test in accordance with ISO 8984 -
Diesel engines – Testing of fuel injectors. However, the tester shall have a powered automated
pumping action and shall not feature a hand-lever-operated pumping action.
E3.1.3. Tests performed. The tester shall perform multiple tests to verify the operational
condition of the Appendix E units under test. These tests shall include the nozzle opening
pressure, chatter (atomization), spray pattern, seat leakage, and back-leakage tests as described in
ISO 8984 - Diesel engines – Testing of fuel injectors – Part 2: Test methods.
E3.1.4. Specifications. The tester shall feature electronic pressure and volume measuring and be
able to control all of the electronics of the Appendix E units under test necessary to verify their
operational condition. The tester shall have a lighted spray chamber and also extract the fumes
generated during the tests.
E3.2. General tester requirements.
E3.2.1. See section 3.
E4. Verification / Demonstration.
E5. Packaging.
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Appendix F:
Required Units Under Test
F1. Testing.
F1.1. Disclaimer. Table F1 contains a list of vehicles and equipment with their associated diesel
fuel injection system components. Table F1 does not have a complete listing of the
manufacturers and part numbers of these items; however, all diesel fuel injection system
components from the vehicles and equipment listed in Table F1 shall be tested using the test
equipment described in this document.
F1.2. Units under test. All diesel fuel injection system components from the vehicles and
equipment listed in Table F1 require testing. These items shall be the units under test. The test
equipment described in this document shall be able to test all of the units under test in Table F1
to full load and through full confirmation of operation as detailed in the specific appendix for the
test equipment.
F1.2.1. List accuracy. Not all of the items in the list are properly described by their manufacturer
and part number. These items may be listed by the manufacturer of the end item, the group who
created or who owns the drawings, by a resaler or rebuilder of the unit, or by National Stock
Number (NSN). If any item in the list appears to be an error, please contact the COR
immediately, to confirm that the correct item is called out and that the requirement to test that
unit is valid. Note that one of each of all units under test from the vehicles and equipment listed
in Table A1 shall be provided with the initial production unit to properly confirm that the test
equipment can test the items, as stated in F1.2.4.
F1.2.2. List completeness. Some items on the list are blank. The correct unit for this end item has
not yet been identified. The testers are required to test these units, even though they are not yet
identified.
F1.2.3. List multiples. Many end items on the list have multiple lines under them. This is because
the end item is fitted with different units in different versions or applications. The tester is
required to test all of the different units in the list, even though the end item is the same for
different units.
F1.2.4. List testing. In order to confirm that all units under test listed in Table F1 are able to be
tested, each unit under test from the vehicles and equipment listed shall be supplied by the
contractor with the initial unit for testing. All materials purchased will become Government
owned. No units are required in further purchases. For more information, see the testing section
4.5.23.
Page 32 of 36
22 April 2011
Table F1
Units Under Test
Platform Info Engine Info Fuel Injection System Info Fuel Pump Injectors / Nozzles
6.2L PRE 1990
PN DB2829-4523
NSN 2910-01-199-2355 6.2L
CAGE 84760 PN 14059057
NSN 2910-01-150-0950
6.2L POST 1990
PN DB2829-4879 PN 14063606
NSN 2910-01-326-9221 NSN 2910-01-280-4283
CAGE 84760
6.5L
PN DB2831-5149
HMMWV TAM D1158 Stanadyne DB2 mechanical fuel
GM 6.2L, 6.5L, 6.5L Turbo NSN 2910-01-414-1272
Truck, Utility M998 injection pump with nozzels 6.5L
CAGE 84760
NSN 2320-01-107-7155 PN 5743795
PN DB2831-5209
NSN 2910-01-379-3752
NSN 2910-01-467-9029
CAGE 84760
6.5 Turbo
DB2831-5485
NSN 2910-01-467-9085 6.5L TURBO
CAGE 84760 PN 10233973
DB2831-5079 NSN 2910-01-399-1848
NSN 2910-01-434-8597
CAGE 84760
TAM D0198
MK23 Mechanically actuated PN 212-3463
Medium Tactical Vehicle Caterpillar C-12 electronic
NSN 2320-01-465-2174 electronically controlled unit NSN 2910-01-518-3531
Replacement (MTVR) control, Adam III
MK25 injection system (MEUI) CAGE 11083
NSN 2320-01-465-2176
TAM D0209 Detroit Diesel 8V-92TA
PN 5199560 PN 5229630
Logistics Vehicle System (LVS) NSN 2320-01-177-5167 PN 8087-7899 Mechanical Unit Injector
NSN 2910-00-175-9250 NSN 2910-01-125-3996
NSN 2320-01-417-3180 NSN: 2815-01-186-7251
RECOVERY VEHICLE FULLY TAM E1377 MODEL AVDS-1790-8CR American Bosch PSB 12 PN KT8829-1 PUMP, FUEL,
PN E9AR110-0110
TRACKED M88A2 NSN 2815-01-414-6821 mechanical fuel injection pump METERING 13 MM
NSN 2910-01-439-9834
M88A2 NSN 2350-01-390-4683 12 Cylinder with nozzles NSN 2910-01-435-1710
Mechanically actuated PN 249-0702
Truck Wrecker (LVS-R) TAM D1214
Caterpillar C-15 electronically controlled unit NSN 2910-01-578-6104
LVSR Wrecker NSN 2320-01-543-0651
injection system (MEUI) CAGE 11083
PUMP, FUEL (P7 and C7)
PN 4000532
Cummins PT (Type G) AFC; R7 NSN 2910-01-490-0856 INJECTOR
ASSULT AMPHIBIAN VEHICLE TAM E0846
Cummins VTA903-T525 (V-8) (Recovery Vehicle) Variable PN 3411827
(AAV) NSN 2350-01-081-8138
Speed (VS) PUMP, FUEL (R7) NSN 2990-01-490-0846
PN 3028795-9104
NSN 2910-01-166-8379
PN 5226240
LIGHT ARMORED VEHICLE TAM E0947 PN 23515518
Detroit Diesel 6V53T Mechanical Unit Injector NSN 2910-01-234-7373
(LAV) NSN 2320-01-123-1602 NSN 2910-01-464-2389
Model 5C55
DIESEL ENGINE PN 714870-51700 PN 714350-53100
3KW Tactical Quiet Generator TAM B0730
MODEL L70AE-DEGFR NSN 2910-01-477-1311 NSN 4820-01-465-8386
MEP-831, 60 HZ NSN: 6115-01-285-3012
NSN 2815-01-465-5993 CAGE: S4163, 0AK42 CAGE: S4164, 0AK42
Page 33 of 36
22 April 2011
Table F1
Units Under Test
TAM B0891 PN 186-6151 PN 186-6168
10KW Tactical Quiet Generator
MEP803A PN 88-21040 NSN 2910-99-301-6898 NSN 2910-01-355-6028
MEP-803, 60 HZ
NSN: 6115-01-275-5061 CAGE 44940 CAGE 44940
805A 805A
MEP805A/815A PN 04806 PN RE38087-1
TAM B0953 MODEL 4039TF002 NSN 2910-01-359-6543 NSN 2910-01-333-2309
MEP805A NSN 2815-01-350-2208 CAGE: 84760 CAGE 75160
30KW Tactical Quiet Generator
NSN 6115-01-274-7389
MEP-805 A/B, 60 HZ
MEP805B MEP805B/815B 805B 805B
NSN: 6115-01-461-9335 MODEL 4045TF151 PN RE67563 PN RE48786
NSN 2815-01-462-2289 NSN 2910-01-507-3192 NSN 2910-01-460-8973
HMMWV TAM D1158 Stanadyne DB2 mechanical fuel CAGE 66836 CAGE 75160
GM 6.2L, 6.5L, 6.5L Turbo 806A
Truck, Utility M998 injection pump with nozzels 806A
MEP806A PN RE40409
NSN 2320-01-107-7155 PN RE38087-1
TAM B1021 MODEL 6059TF002 NSN 2910-01-363-6833
NSN 2910-01-333-2309
MEP806A NSN 2815-01-350-2209 CAGE 75755, 75160
60 KW Tactical Quiet Generator CAGE 75755, 75160, Z09R4
NSN 6115-01-274-7390
MEP-806 A/B, 60 HZ
MEP806B MEP806B 806B
806B
NSN 6115-01-462-0291 PN 6068TF151 PN RE67563
PN RE75160
NSN 2815-01-462-3596 NSN 2910-01-507-3192
CAGE 66837
CAGE 66836
Caterpillar 3306 PN 2401673
TAM B2462
Tractor, Medium (D7G) PN 5R6935 PN 2WO259 NSN 2910-01-169-9753
NSN 2410-01-155-1588
NSN 2315-01-161-4944 NSN 2910-01-175-1952
Cummins QSC 8.3-C305 PN 3973228
TAM B0038 PN 4903254
All Terrain Crane (MAC 50) PN 31471412 NSN 2815-01-566-9629
NSN 3810-01-538-4030 CAGE 15434
NSN 2815-01-555-8200 CAGE 15434
PUMP, FUEL , METERING
INJECTOR
PN 7N6389
PN 8N9457
NSN 2910-01-199-8084
NSN 2910-01-131-0101
DV-43 Caterpillar V8 Model 3408T CAGE 11083
Container Handler (RTCH) TAM B0391 PN 5R4536
INJECTOR
NSN 3930-01-269-4938 NSN 2815-01-109-4374 HOUSING, FUEL PUMP
PN 2W3390
PN 7N4574
NSN 4820-01-179-5546
NSN 2910-01-286-4878
CAGE 11083
CAGE 11083
PN 4026222
Cummins QSM 11 (400 hp)
NSN 2915-01-515-9496
RT-240 PN 922784.927 (SN >400)
CAGE 1NWY2
Container Handler (RTCH - NSN 3930-01-473-3998 PN 12J1335 Electronically controlled unit
Kalmar) TAM B0392 NSN 2815-01-551-1097 NEW injectors
PN 4903319 (SN >400)
NSN 3930-01-522-7364 NSN 2815015505636 RESET
NSN 2910-01-538-4817
CAGE 1NWY2
CAGE 15434
FUEL PUMP
TAM B0589 Cummins V903C (295 hp) PN 3054197
PN 302194B-3999
Excavator, Combat M9 (ACE) NSN 2350-00-808-7100 PN 57K1880 NSN 2910-01-107-1737
NSN 2815-01-179-9056
NSN 2815-01-399-6801 CAGE 15434
CAGE 15434
Page 34 of 36
22 April 2011
Table F1
Units Under Test
INJECTOR
PN 3802035
CUMMINS INC NSN 2910-01-278-5523
TAM B2464
mechanical fuel injection pump PN 3908208 CAGE 15434
Tractor Full Tracked NSN 3805-01-315-1091 J.I. Case 6T-590 (118 HP)
with nozzles NSN 2910-01-281-1083 OR
CAGE 15434 PN J909476
NSN 2910-01-280-4253
CAGE 10988
PN 1294420H92
CUMMINS INC NSN 2910-01-278-5523
TAM B2460
mechanical fuel injection pump PN 3908208 CAGE 29510
Tractor Full Tracked (T5) NSN 2460-01-254-1667 J.I. Case 6T-590 (118 HP)
Stanadynewith
DB2nozzles NSN 2910-01-281-1083 OR
HMMWV TAM D1158 mechanical fuel
GM 6.2L, 6.5L, 6.5L Turbo CAGE 15434 PN 3802035
Truck, Utility M998 injection pump with nozzels
NSN 2320-01-107-7155 CAGE 15434
MODEL TX51-19M MODEL TX51-19M
MODEL TX51-19M PN U2644D057 PN 2645M004
TAM B2566 Perkins 704-30T (80 HP) NSN 2910-01-495-9991 NSN 4730-01-495-8645
MODEL: TX51-19M CAGE 49185 CAGE 49185
Forklift, Light Capability, Rough
NSN: 3930-01-478-3519
Terrain (LCRTF)
MODEL: TX51-19MD MODEL TX51-19MD MODEL TX51-19MD
NSN: 3930-01-533-0855 MODEL TX51-19MD PN 0428 6792, 0134 0330, 0134 PN 0428 6251
Deutz BFM 2011 (81.6 HP) 0331, 0134 0332, 0134 0333 NSN 2910-12-366-6425
CAGE 62445 CAGE 62445
TAM B2561
Forklift, Extendable Boom (New
NSN 3930-01-488-2151 Cummins QSB 4.5T
EBFL)
NSN 3930-01-508-0886
Cummins NTC 400 Cummins PT (Type G) Pump Cummins PT Type D Injectors
PN D093410BX02 PN 3060697-3986 PN 3047980
NSN 2815-01-184-9118 NSN 2910-01-198-7312 NSN 2910-01-217-5757
CAGE 15434 CAGE 15434 CAGE 15434
TAM D1064
Truck, Fire Fighting P-19A
NSN 4210-01-137-9943
APU INJECTION PUMP APU INJECTOR ASSY
AUX POWER UINT (APU) PN 500-0590-044 PN 500-6615-032
Lombardini (6 HP) NSN 2910-01-230-5632 NSN 2910-01-230-9046
PN 6LD325 CAGE 51879 CAGE 51879
PN 2W3390
NSN 4820-01-179-5546
Caterpillar 3406 (330 HP) PUMP, FUEL, METERING
TAM B1922 CAGE 11083
PN 5R6706 PN 8N5533
SCRAPER NSN 3805-01-153-1854
NSN 2815-01-171-8490 NSN 2910-01-127-4022
PN 9L6884
CAGE 11083 CAGE 11083
NSN 2910-01-066-5410
CAGE 11083
PN 7N0449
NSN 2910-01-143-4403
TAM B1082 Caterpillar 3304 PUMP, FUEL, METERING
CAGE 11083
NSN 3805-01-150-4795 PN 5R7277 PN 2W0263
Motorized Road Grader
NSN 2815-01-188-7440 NSN 2910-01-152-7834
PN 8N7005
CAGE 11083 CAGE 11083
NSN 2910-01-169-9758
CAGE 11083
New 120M Motorized Road TAM B0078
CAT C6.6 (138-173HP)
Grader NSN 3805-01-566-0558
Page 35 of 36
22 April 2011
Table F1
Units Under Test
NOZZLE, FULE INJECTION
TAM B2567 John Deere 6076 (185 HP) PUMP, FUEL, METERING
PN RE30159
Tractor, Rubber Tired (TRAM) NSN 3805-01-279-3635 PN RG6076ADW02 PN RE35847
NSN 2910-01-323-7360
NSN 2815-01-316-2669 NSN 2910-01-325-5746
CAGE 75755
John Deere 6 cyl 6.8L
TRACTOR, RUBBER TIRED, TAM B0063 PN RE533508 PN RE534111
Model #: PE6068HDW67
ARTICULATED STEERING, MODEL 624KR Common Rail Fuel Injection NSN 2910-01-566-0465 NSN 2910-01-567-3423
PN RE534832
MULTI-PURPOSE (TRAM) NSN: 3805-01-549-7814 CAGE 75755 CAGE 75755
NSN 2815-01-566-0376
MK I AND II SABER ENGINE SABER ENGINE
Sabre Engines Ltd. PN 49398 PN 5209003
MODEL 212 (212 HP) NSN 2910-01-121-5173 NSN 2910-99-214-8553
TAM B0114 CAGE U2340 CAGE U0041
HMMWV TAM D1158 Stanadyne DB2 mechanical fuel
BOAT, Bridge Erection NSN 1940-01-218-9165 GM 6.2L, MK
6.5L,III6.5L Turbo
Truck, Utility M998 injection pump with nozzels
Cummins Engine Ltd. CUMMINS ENGINE CUMMINS ENGINE
NSN 2320-01-107-7155
MODEL 6BT 5.9-M (210 HP) PN 4020108 PN 4089254
PN 13226E0412 NSN 2910-01-538-6094 NSN 2910-01-537-2159
NSN 2815-01-233-8393 CAGE 15434 CAGE 15434
TAM B0446 Cummins 4B3.9 SPEC SES1108 PN 3908580 PN 3802037
Air Mobile Crane (7.5 TON) NSN 3810-01-165-0646 PN 709 1300 NSN 2910-01-259-4436 NSN 2910-01-448-6911
NSN 2815-01-239-1774 CAGE 15434 CAGE 15434
TAM D0026 Mack ASET 400 AI (400 HP) UNIT PUMP INJECTOR / NOZZLE
NSN 2320-01-529-2251 PN 11GB22738Y Electronic Unit Pump (one per PN 313GC 5230M PN 736GB 419M2
MRAP Buffalo MK-1
MK 2 NSN 2815-01-537-2689 cylinder) and nozzles NSN 2910-01-544-2182 NSN 2910-01-546-4325
NSN 2320-01-531-6425 CAGE 89619 CAGE 89619 CAGE 89619
CAT 3116TA
TAM B0024 PN 1278216
175hp@2300RPM PN 1333062
Water Distributer NSN: 3825-01-497-0690 NSN 2910-01-474-1834
PN 1187663 CAGE 11083
613CWD CAGE 11083
NSN 2815-01-517-0223
CAT C3.4
TAM B0040 Mitsubishi 3044C-T
CAT CAT
Multi-Terrain Loader NSN 3805-01-550-0883 PN 262-7289 (S/N: CJS61913-
PN 317-5045 PN 227-1028
277C UP)
NSN 2815-01-565-4987
John Deere 6 cyl, 9.0L John Deere
TAM B0060 John Deere
Model # RG6090HT001 PN RE537541
Medium Crawler Tractor (MCT) NSN 2320-01-558-5671 Common Rail Fuel Injection PN RE537393
PN: RE537203 NSN 2910-01-571-8432
850JR CAGE 75755
NSN 2815-01-570-0260 CAGE 75755
420D
420D
TAM B2483 CAT 3054C 420D
PN 236-1674
420D IT PN 242-9917 PN 237-5214
NSN 2910-01-523-8346
NSN 3805-01-514-7166 NSN 2815-01-524-0580
Backhoe Loader (BHL)
420E
420E IT 420E 420E
PN 236-1674
NSN 3805-01-557-4003 CAT 3054C PN 274-4962
NSN 2910-01-523-8346
PN 318-8392
Page 36 of 36

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

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

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

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

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

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

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

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

4.5. Test equipment verifications.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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