0106-6301 Specifications.pdf

CABLE PULLING MACHINE

1. SCOPE. This document provides technical specifications for the procurement of a self-propelled, diesel powered cable-pulling unit with a 24,000 pound line pull for temporary service use.

2. APPLICABLE REFERENCES. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on the date of invitation for bids shall apply.

a) MIL-C-5541, Chemical Conversion Coatings on Aluminum and Aluminum Alloys

b) MIL-A-8625, Anodic Coatings for Aluminum and Aluminum Alloys

c) 29 CFR Chapter XVII, Part 1926 Subpart H, Materials Handling, Storage, Use and Disposal

d) 29 CFR Chapter XVII, Part 1910 Subpart S, Electrical

e) 29 CFR Chapter XVII, Part 1910 Subpart O, Machinery and Machine Guarding

3. REQUIREMENTS.

3.1 GENERAL REQUIREMENTS.

3.1.1 NEW DEVELOPMENT. If, during the contraction period, any new developments are generated that would improve the efficiency, accuracy or productivity of the equipment and its related equipment or decrease its operation cost, the contractor shall notify the Contracting Officer. Reports of such developments shall be addressed to the Contracting Officer.

3.1.2 SAFETY AND HEATH REQUIREMENTS. Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts. Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of "OSHA Safety and Health Standards (29 CFR Chapter XVII, part 1910), General Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other paragraphs of this specification. The design and manufacture shall be in accordance with all applicable OSHA safety standards.

3.1.3 OSHA APPROVED CERTIFICATION. The equipment installation and its component parts shall be in compliance with the applicable OSHA regulations in accordance with CFR Title 29, Chapter XVII, Part 1910 and installed in accordance with NEC/NFPA requirements.

Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399. After equipment delivery, and prior to testing, the contractor shall provide an OSHA Certification Report. Failure to provide this certification report will delay acceptance of the equipment, and could result in rejection for failure to comply with the terms of the contract. This report documents the results of all tests performed, provides an assessment of the equipment performance for compliance with the contract requirements, and forms a basis for recommending a safety certification. The report, test and evaluation shall be a composite of those inspection requirements specified in the contract. The report shall be prepared in an orderly manner to clearly and accurately set forth the collected data and conclusion resulting from these inspection requirements, opinions and subjective conclusions shall be clearly identified.

The report shall include, but is not limited to, the following:

1. List of all tests performed and by whom witnessed.

2. List of data used for evaluation.

3. Tabulation of all discrepancies related to specification performance requirements.

4. Description of limitations revealed by data utilized.

5. Actions taken to mitigate each discrepancy and limitation.

6. Recommendations for subsequent actions.

7. Summary conclusions.

8. Manufacturer Certification that equipment has been manufactured and installed to OSHA CFR 1910.399 (per definition of “acceptable”).

3.2 MATERIALS

3.2.1 FERROUS PARTS. All exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall be chrome plated, galvanized or otherwise surface protected by an electrical/chemical process or of stainless steel to resist corrosion in a salt-laden moist, variable temperature environment.

3.2.2 ALUMINUM PARTS. All aluminum parts for use outdoors shall be anodized in accordance with MIL-I-8625 or chemically treated in accordance with MIL-C-5541, followed by two coats of weather-resistant exterior paint.

3.2.3 DISSIMILAR METALS. Intimate contact between dissimilar metals which can be expected to cause galvanic corrosion shall be avoided as much as practicable. When such contact cannot be avoided, an interposing insulating material shall be provided to minimize the corrosion effect.

3.2.4 MERCURY RESTRICTION. The equipment shall neither contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.2.5 ASBESTOS RESTRICTION. The use of asbestos and materials containing asbestos on or in the furnished equipment is prohibited.

3.2.6 POLYCHLORINATED BIPHENYL (PCB) RESTRICTION. The use of polychlorinated biphenyl on or in the equipment is prohibited.

3.2.7 CADMIUM RESTRICTION. The use of cadmium and materials containing cadmium on or in the furnished equipment is prohibited.

3.2.8 LITHIUM RESTRICTION. The use of lithium and materials containing lithium on or in the furnished equipment is prohibited.

3.2.9 METHYLENE CHLORIDE RESTRICTION. The use of methylene chloride and materials containing methylene chloride on or in the furnished equipment is prohibited.

3.2.10 LEAD RESTRICTION. The use of lead and materials containing lead on or in the furnished equipment is prohibited.

3.3 WORKMANSHIP

3.3.1 STEEL FABRICATION. The steel used in fabrication shall be free from kinks, sharp bends, and other conditions that would be deleterious to the finished product. Manufacturing processes shall not reduce the strength of the steel to a value less than intended by the design.

Manufacturing processes shall be done neatly and accurately. All bends shall be made by controlled means to ensure uniformity of size and shape.

3.3.2 BOLTED CONNECTIONS. Boltholes shall be accurately punched or drilled and shall have the burrs removed. Washers or lock washers shall be provided in accordance with good commercial practice, and all bolts, nuts, and screws shall be tight.

3.3.3 RIVETED CONNECTIONS. Rivets may be used for minor attachments (e.g., label plates). Rivets shall not be used for main structural support. Rivet holes shall be accurately punched or drilled and shall have the burrs removed. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads, when not countersunk or flattened, shall be of an approved shape and of uniform size for the same diameter of rivet. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the member.

3.3.4 WELDING. Welding procedures shall be in accordance with a nationally recognized welding code. The surface of parts to be welded shall be free from rust, scale, paint, grease, or other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the parts connected by the welds. Welds shall transmit stress without permanent deformation or failure when the parts connected by the weld are subjected to proof and service loadings.

3.4 GENERAL DESCRIPTION. Single operator, diesel powered cable-pulling unit with a hydrostatic drive system. Line-pull capacity shall be a minimum of 24,000 pounds. Diesel generator shall be integral to the unit with a minimum continuous power rating of 30-horse power. All controls and gauges shall be water proof.

3.5 DIESEL ENGINE. Diesel engine shall be water cooled with electric start, preheat capability, and integral block heater for cold weather start. Engine shall meet the following requirements:

3.5.1 Front and rear control

3.5.2 Electric throttle activation at all control points

3.5.3 Closed loop hydrostatic system

3.5.4 Two-speed final drive

3.5.5 Chrome plated drive shaft with pillow block bearings

3.5.6 Lighted gauges for oil pressure, water temperature, tachometer, hour meter, ammeter, fuel level, and engine preheat.

3.5.7 Enclosed battery compartment with external battery connector

3.5.8 Fully hooded with hinged doors

3.5.9 Auxiliary power shaft with bayonet

3.5.10 Auxiliary pressure gauge at control valve bank

3.5.11 Hydrostatic pressure gauge at front control panel

3.5.12 Full flow filtration with relief and condition indicator and replaceable cartridge

3.5.13 Hydraulic oil cooler

3.6 MAIN FRAME. Frame shall meet the following requirements:

3.6.1 Reinforced drawbar with replaceable towing eye and safety chains

3.6.2 Fully welded fenders and integrated tool box

3.6.3 Two-point T-handle latches w/locks and full length piano hinged tool box doors

3.6.4 20,000 pound stub spindle axle

3.6.5 Air brakes with anti-lock braking system

3.6.6 Double shock mounted lights with pigtail connectors

3.6.7 Multi-pocket vertical lift hydraulic mandrel racks with mechanical locks and stabilizers

3.6.8 Heat treated reel mandrel with centering cones and locking collars

3.6.9 Hydraulically raised and lowered drawbar with load locked cylinder

3.6.10 Hydraulically powered idler wheel with power steering system and anti-cavitation valves

3.6.11 Hydraulic control valve with pressure relief gauge

3.6.12 Stainless steel hydraulic tubing

3.7 CONTROLS.

3.7.1 Main Control Panel: shall contain all engine and pulling controls and associated gauges. The main control panel shall allow the operator proportional control of the units pulling force. The controller shall return to the neutral position and automatically stop all pulling when the operator releases the control. The dual speed control shall have the capability of being shifted during the pull without halting the pull. All switches and gauges shall be waterproof.

3.7.2 Rear Control Panel: shall be located at the rear fender. Operator shall have a clear view of pulling operations when positioned at the rear control panel. Rear control panel shall provide the operator control of all pulling operations, engine throttle, and speed control. Rear control shall be electronically isolated from the front control panel to prevent electrical back-feed and from allowing the two control panels from controlling the pulling operations at the same time.

3.7.3 Hydraulic Controls: Centrally located control valves. Hydraulic controls shall provide control over the lifting cylinders, sliding capability of the power unit, drawbar height adjustment, and power steering control. Controls shall be spring loaded to return to the neutral position. A hydraulic pressure gauge shall be installed in a conspicuous location near the hydraulic controls to allow the operator to view the gauge while using the hydraulic controls. Additional hydraulic controls for power steering shall be located to the side of the unit.

3.8 LOADING

3.8.1 Hydraulic Loading: Unit shall be of an open yoke design with multiple pocket lifting racks with uniform ground clearance and low center of gravity. Lifts shall be stabilized and mechanically locked to relieve load from cylinders with weight transferred to the trailer mainframe. No supporting equipment shall be required during the loading process. Cylinders shall be capable of handling reels up to 20,000 pounds.

3.8.2 Load Adjustable: Shall be capable of accommodating reels up to 108 inches in diameter and 56 inches wide. Power unit shall be capable of sliding forward and aft using hydraulic controls in order to adjust for different size reels. Drive roller housings shall be adjustable to handle differing reel widths.

3.9 MANEUVERABLE. Unit shall not be required to be positioned or located by its towing vehicle. The unit shall be easily maneuvered using a hydraulically powered steering system with a hydraulically powered idler wheel. Unit shall allow one person to easily maneuver the unit where a truck physically cannot fit.

3.10 FRICTION DRIVE. Unit shall provide an independent drive roller housing to provide four roller contact at all times, regardless of reel shape. The unit shall contain flange bearings and chain slack adjusters, as well as chrome plated drive roller axles and drive shaft.

3.11 TRAILER. The configuration of the unit shall make it trailer compliant with on-road use nation-wide (i.e., brake/running lights & turn signals, etc.). Tires and wheels shall be suitable for highway travel fully loaded with wound electrical cable reels. Tires shall be radial and rated for 120 psi (min), 365/80R20, 20 Ply (or better) with heavy duty rims.

3.12 WEATHER PROTECTION. Units control boxes shall be Nema 4 (min). All other integral equipment enclosures installed on the unit shall be Nema 3R rated for operation in blowing rain. Unit shall have an Acrylic Urethane finish suitable to protect all metal parts in a marine weather environment.

3.13 DIMENSIONS & WEIGHT. Unit shall not exceed the following dimensions: Length: 200 inches, Width: 94 inches, Height: 82 inches. Total weight shall be no more than 8000 pounds.

3.14 AUXILIARY EQUIPMENT. All equipment required for proper operation of the pulling unit shall be integral to the unit or contained within the trailer. No external control power shall be required.

3.15 CLEANING, TREATMENT AND PAINTING. The entire enclosure shall be painted.

Surfaces to be painted shall be cleaned and dried to insure that they are free from scale, water, dirt, corrosion product, or any other contaminating substances. As soon as practicable after cleaning, and before any corrosion product or other contamination can result, the surfaces shall be prepared or treated to insure the adhesion of the coating system. The painting shall consist of at least one coat of primer and at least two finish coats of weather resistant exterior paint.

The primer shall be applied to a clean, dry surface as soon as practicable after cleaning and treating. Painting shall be with manufacturer's current materials according to manufacturer's current processes and the total dry film thickness shall be not less than 2.5 mils over the entire surface. The final painted appearance shall be smooth and free from defects. Only lead-free and chromate-free materials shall be used.

3.16 LABELING REQUIREMENTS. The equipment shall be labeled as follows:

3.16.1 INSTRUCTION PLATES. Wording and numbers on all control panels, instruments, charts and plates shall be permanently and legibly displayed in bold face, English language characters on a contrasting background. Stencil the design load weight and line pull rating on at least one side of the enclosure.

3.16.2 CAUTION/WARNING PLATES. Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment in prominent, visible locations. All safety precautions to be observed by the operator or maintenance personnel shall be permanently marked on the plates.

3.16.3 IDENTIFICATION PLATE. A corrosion resistant identification plate shall be securely and conspicuously placed on the equipment. It may be the manufacturer's standard, but, as a minimum, it shall contain the following information:

3.16.3.1 Nomenclature.

3.16.3.2 Contractor's name.

3.16.3.3 Manufacturer's model designation.

3.16.3.4 Manufacturer's serial number.

3.16.3.5 Contract number.

3.16.3.6 Date of manufacture.

3.16.4 TECHNICAL DATA. Provided technical data, written in the English language, shall contain, as a minimum, the following information:

3.16.4.1 General introductory information including pictures displaying the identity and location of components.

3.16.4.2 Specifics of "as built" circuit breaker and enclosure characteristics.

3.16.4.3 Technical manual for the pulling unit including theory of operation, instructions for operation and settings, and basic troubleshooting guidelines.

3.16.4.4 Listing of replacement parts with ordering information.

3.16.4.5 All required maintenance information.

3.16.4.6 Test data and documentation with certification signature(s) reflecting the satisfactory accomplishment of tests performed in paragraphs 4.2 and 4.4.

3.16.4.7 A schematic diagram of all electrical connections in the enclosure.

3.16.4.8 One or more CD-ROM or DVD-ROM disk(s) containing all technical data listed above in Adobe PDF format.

4. QUALITY ASSURANCE PROVISIONS. The contractor shall conform to quality assurance, inspection and testing criteria as follows:

4.1 RESPONSIBILITY FOR INSPECTION. The contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The contractor shall be responsible for ensuring that the equipment provided meets all requirements of Section 3. The Government reserves the right to perform additional inspections and to reject the equipment provided if these inspections show that the equipment does not meet all requirements of Section 3.

Only supplies that completely conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection.

4.2 EXAMINATION. The equipment shall be examined to determine compliance with all requirements of this specification. The supplies offered for delivery shall be examined for design, construction, components, electrical equipment and workmanship to determine conformance with the requirements of this specification.

4.3 TESTS AT ORIGIN. At a minimum, the following tests shall be carried out by the manufacturer or manufacturer’s representative prior to delivery of the equipment.

4.3.1 OPERATIONAL TEST. Drive the unit around under its own power ensure all control points are capable of driving and steering the unit. Start the unit and ensure all moveable surfaces operate as designed. Perform a cable pull test to ensure the unit is capable of exerting pull forces up to 24,000 pounds of line pull. Perform the operation test once using the main control panel and once using the rear control panel.

4.3.2 TEST AND EVALUATION REPORT. A test and evaluation report shall be prepared by the contractor documenting all readings and results that were recorded during the performance of paragraphs 4.2 and 4.4, including any defects found, repairs that were made and documentation of the subsequent retesting. This test and evaluation report shall be provided to the Government along with the equipment.

4.3.3 WARRANTY. Contractor shall provide a warranty period in writing covering all parts and labor associated with the repair of the circuit breaker. When possible, all repairs covered by warranty shall take place on site. Warranty shall commence from the date of acceptance of the circuit breaker. Warranty period shall be no less than three (3) years from date of acceptance.