DTP_DOS Armoved Vehicles_19MAR19.pdf

FOR OFFICIAL USE ONLY

Detailed Test Plan for the

Automotive Test of the

U.S. Department of State (DOS) Armored Vehicles

ATEC Project No. 2019-DT-ATC-FEDSP-H3752

Donald Hirt Light Tactical Vehicles Branch, Tactical Vehicles

Division, Automotive Directorate

March 2019

Plan Produced by:

U.S. Army Aberdeen Test Center

Aberdeen Proving Ground, MD 21005-5059

Plan Produced for:

U.S. Department of State

Springfield, VA 22153-2810

Distribution controlled by U.S. Department of State.

The use of a trade name or the name of the manufacturer or a contractor in this plan does not constitute an official endorsement or approval of the use of such commercial hardware or software or of service. The test plan may not be cited for purposes of advertisement.

DISPOSITION INSTRUCTIONS: Destroy this document when no longer needed. Do not return to the originator.

This document contains information EXEMPT FROM MANDATORY DISCLOSURE under the

Freedom of Information Act. Exemption 5 (predecisional materials) applies.

DRAFT

DEPARTMENT OF THE ARMY

U.S. ARMY ABERDEEN TEST CENTER

6943 COLLERAN ROAD, BUILDING 400

ABERDEEN PROVING GROUND, MD 21005-5059

FOR OFFICIAL USE ONLY

TEAT-ADV

MEMORANDUM FOR U.S. Army Evaluation Center (TEEC-MS-T/Martin Bindel), 6617 Aberdeen Boulevard, Aberdeen Proving Ground, MD 21005-5001

SUBJECT: Detailed Test Plan for the Automotive Test of the U.S. Department of State (DOS) Armored Vehicles, ATEC Project No. 2019-DT-ATC-FEDSP-H3752

1. Subject test plan has been approved by this test agency and is submitted for your information and retention.

2. The point of contact for this office is Mr. Donald Hirt, TEAT-ADV, DSN 298-7489.

FOR THE COMMANDER:

Encl KENNETH L. HUDSON Director, Automotive Directorate i

TABLE OF CONTENTS

Note: To use the hyperlinks in this test plan, click on the blue, underlined text.

PAGE

SECTION 1. INTRODUCTION

1.1 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION 2. SUBTESTS

2.1 INITIAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1-1

2.2 PHYSICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2-1

2.3 BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3-1

2.4 SPEED AND ACCELERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4-1

2.5 STEERING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-1

2.6 ENDURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6-1

2.7 FINAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7-1

SECTION 3. APPENDIXES

A TEST CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1 B TEST SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1 C INFORMAL COORDINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1 D REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1 E ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1 F DISTRIBUTION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1

1-1

SECTION 1. INTRODUCTION

1.1 SYSTEM DESCRIPTION

1.2 SUMMARY

a. Testing Authority. On 11 December 2018, the U.S. Army Test and Evaluation Command (ATEC) authorized the U.S. Army Aberdeen Test Center (ATC), Aberdeen Proving Ground (APG), Maryland, to plan, conduct, and report the Automotive Test of the U.S. Department of State (DOS) Armored Vehicles. This was done through the establishment of an ATEC test project (app D, ref 1).

b. Test Concept. This effort is in support of the automotive portion of the First Article Test Acceptance of the DOS armored vehicles.

c. DOS will provide seven or more armored vehicles. ATC will provide the facilities, instrumentation, and personnel required to perform testing. The ATC test officer will be responsible for overall test control. Engineers and technicians will perform all laboratory testing.

All quantitative data will be measured using instrumentation calibrated to standards traceable to the National Institute of Standards and Technology (NIST).

d. A summary of the test objectives is presented in Table 1-1.

TABLE 1-1. TEST OBJECTIVES

Subtest Objective

2.1 - Initial Inspection Determine whether the test vehicles are in operational and safe condition, and identify any defects or damage.

2.2 - Physical Characteristics

Measure pertinent dimensional and physical characteristics of the test vehicles.

2.3 - Braking Characterize and assess the capabilities of the service brake system of the test vehicles.

2.4 - Speed and Acceleration

Determine the speed and acceleration characteristics of the test vehicles.

2.5 - Steering and Handling

Determine the steering and handling characteristics of the test vehicles.

2.6 - Endurance Determine the reliability characteristics of the test vehicles.

2.7 - Final Inspection Determine the physical condition of the test vehicles at test completion.

2.1-1

SECTION 2. SUBTESTS

2.1 INITIAL INSPECTION

2.1.1 Objective

Determine whether the test vehicles are in operational and safe condition, and identify any defects or damage.

2.1.2 Criterion and Data Analysis/Procedure

TABLE 2.1-1. CRITERION AND DATA ANALYSIS/PROCEDURE

Criterion (App A Item) Remark/Analysis 1 - Workmanship Operational and visual inspections will be conducted to verify the vehicle has no evidence of cracks, dents, scratches, burrs, sharp edges, loose parts, foreign matter, or any other evidence of poor workmanship. The cab, chassis and bodies will be inspected to determine if normal vehicle operation does causes any chafing, binding or other damage to any harness, hose, control cable, lanyard, tube or line.

2.1.3 Test Procedures and Data Required

a. Test Operations Procedure (TOP) 2-2-505 (ref 2), paragraph 4.1, will be used as a general guide to conduct the initial inspection. Limited visual and functional inspections will be conducted on the vehicle to ensure that no damage is present and that the vehicles are in satisfactory condition for test operation. Components and assemblies will not be disassembled for inspection, repair, or adjustment unless a safety hazard exists and prior approval by DOS is obtained.

b. The vehicle’s serial numbers, manufacturer identification information, and other pretest identification data will be recorded in a Test Incident Report (TIR).

c. The test item will be assigned an ATC test item identification number (TIIN) and will be referred to by this TIIN throughout testing.

d. Preventive maintenance checks and services (PMCS) will be performed in accordance with supplied manuals.

e. As delivered tire pressures will be recorded. Tire pressures will be adjusted if the measured tire pressures do not coincide with manufacturer’s recommended tire pressure.

f. All loose items will be inventoried and properly stowed in accordance with supplied documentation. In absence of supplied documentation, items will be secured in logical locations and their associated position will be recorded in a TIR.

2.1-2

g. Inspections will include but not be limited to the following major subsystems:

Body Chassis Interior components and workspace Engine and engine accessories Drive line Wheels and tires Suspension system Steering system Cooling system Braking system Electrical system Fuel system Exhaust system Gauges and instrumentation Corrosion control (painting)

h. General views of the test items will be photographed. Photographs will also be taken of the manufacturer’s identification placard located on the door frame.

i. The following data are required:

All defects, damage, and safety issues Record of components not functional or operating properly Major component serial numbers Tire pressures, kPa (psi) General view photographs

2.2-1

2.2 VEHICLE CHARACTERISTICS

2.2.1 Objective

Measure pertinent dimensional and physical characteristics of the test vehicles.

2.2.2 Criterion and Data Analysis/Procedure

TABLE 2.2-1. CRITERION AND DATA ANALYSIS/PROCEDURE

2 - Tire/Wheel The wheel and tire ratings at the vehicle manufacturer’s recommended tire pressure will be compared to the gross axle weight rating (GAWR) to determine conformance at the maximum speed of the vehicle.

2.2.3 Test Procedures and Data Required

a. All physical characteristics will be measured with the vehicle payloaded to gross vehicle weight rating (GVWR) with exception of weight distribution, which will be measured both as-delivered and following payloading to GVWR. Each seating position will be loaded with 77 kg (170 lb) and remaining residual weight will be positioned appropriately throughout vehicle to simulate crew gear weight. All physical characteristic measurements will be presented in tabular and/or graphical format, as appropriate, in the final report.

b. TOP 2-2-500 (ref 3) will be used as a general guide to determine limited physical dimensions: length, width, height, track width, and wheel spacing. These physical characteristics will be determined using standard instrumentation including, but not limited to, steel tapes, plumb bobs, straightedges, and clinometers, as required.

c. TOP 2-2-801 (ref 4), paragraphs 4.1.1 and 4.2.1, will be used as a general guide for weight distribution. The weight distribution and total vehicle weight will be determined by sequential weighing of wheels on a calibrated platform scale. Wheel and tire data will be recorded and compared to the weight distribution using the Tire and Rim Association Handbook (ref 5) to determine overload conditions.

d. TOP 2-2-800 (ref 6) will be used as a general guide to determine the center of gravity (CG) of the vehicles. The CG will be determined in three planes using either the weight reaction or suspension method for the vertical CG location and the weight distribution method for the longitudinal and lateral CG locations.

e. The maximum side slope angle and simulated lateral acceleration the vehicles are capable of sustaining prior to rolling over will be determined using the ATC Tilt Table facility.

Testing will be performed in accordance with Society of Automotive Engineers (SAE) J2180 (ref 7). The vehicle will be tilted about its roll axis until the uphill tires lift off the platform, at which point safety cables will restrain the combination from an actual rollover.

2.2-2

f. The following data are required:

Operational configuration payload description Length, width, height, wheel spacing, cm (in.)

Wheel data Tire side wall data Tire pressures, kPa (psi) Relevant weights, kg (lb) Lateral, vertical, and longitudinal CG, cm (in.)

Static rollover threshold, deg

2.3-1

2.3 BRAKING

2.3.1 Objective

Characterize and assess the capabilities of the service brake system of the test vehicle.

2.3.2 Criterion and Data Analysis/Procedure

TABLE 2.3-1. CRITERION AND DATA ANALYSIS/PROCEDURE

3 - Maximum Effort Service Braking

Stopping distances measured and normalized to incremental roads speeds ranging from 32 km/hr (20 mph) to 97 km/hr (60 mph) in 16-km/hr (10-mph) intervals will be compared to Federal Motor Vehicle Safety Standard (FMVSS) 105 (ref 8), Table II, to assess conformance. Antilock braking system (ABS) performance will be monitored visually.

2.3.3 Test Procedures and Data Required

a. General. TOP 2-2-608 (ref 9) will be used as general guide for brake testing. Testing will be conducted with the vehicle at GVWR. The vehicle tires will be inflated to the manufacturer’s recommended pressures for highway operation. All dynamic brake testing will be conducted on a paved, level, dry road surface at the Automotive Technology Evaluation Facility (ATEF) or the Perryman Test Area (PTA) 3-mile straightaway. All dynamic testing will be videotaped.

b. Instrumentation. Basic field braking instrumentation will include a brake pedal force transducer, a global positioning system (GPS)-based velocity sensor, a six-axis inertial sensor (X, Y, and Z acceleration and pitch, roll and yaw rate), and a fifth wheel velocity sensor. All instrumentation will be calibrated and the data will be recorded using a Dewetron digital data acquisition system.

c. Service Brakes.

(1) The braking capability of the vehicle will be determined by measuring the distance required to stop the vehicle at speeds ranging from 32 km/hr (20 mph) to 97 km/hr (60 mph) in 16-km/hr (10-mph) intervals during a full-pedal effort service brake application. At each vehicle speed tested, six stops with the transmission in neutral will be performed with three stops completed in each direction of travel. The initial brake temperature before each stop should be between 66 and 93 ºC (150 and 200 ºF). The brake temperatures will be monitored by the field engineer using an infrared thermometer. All testing will be completed in a 4-m (12-ft) wide lane as marked with conventional traffic pylons. During each stop the driver may use corrective steer as necessary to stay within the lane boundaries.

2.3-2

(2) Testing will initially be conducted with the brakes in their as-received condition. If the system fails to meet the system requirements, the service brakes will be burnished (if directed by DOS) and the test will be repeated with burnished brakes, as described in FMVSS 105.

(3) The vehicle speed at which the brakes are applied, stopping distance, lateral stability, and wheel lockup will be recorded. Stopping distance will be calculated from the first brake control movement to the point where the vehicle speed first reaches zero. Stopping distance measurements will be normalized to the target initial vehicle speed using the procedure described in SAE J299 (ref 10).

(4) Service brake performance results will be presented in tabular form, to include the vehicle speed versus stopping distance and vehicle speed versus average deceleration rate.

Stopping distances for service brake applications from 32 km/hr (20 mph) up to 97 km/hr (60 mph) in 16-km/hr (10-mph) increments will be compared with the applicable stopping distance requirements (based on the vehicle GVWR) presented in FMVSS 105, Table II, column II-2d.

(5) Service brake stopping performance will be considered met if one of the six brake stops required by FMVSS 105 meets the requirement. Failure to stay within the specified 4-m (12-ft) lane width during any brake stop will constitute failure of the service brake system. For the maximum effort brake stops, an average stopping distance and deceleration rate based on the average of six stops, as well as a minimum stopping distance, will be presented.

d. The following data are required:

Stopping distance, each condition, m (ft) Vehicle speed, km/hr (mph) Average deceleration rate, m/s2 (ft/s2) Slew from straight line path, cm (in.)

Problems or failures Observations of instability, vehicle slew, brake system malfunction, or brake component damage

2.4-1

2.4 SPEED AND ACCELERATION

2.4.1 Objective

Determine the speed and acceleration characteristics of the test vehicles.

2.4.2 Criteria and Data Analysis/Procedure

TABLE 2.4-1. CRITERIA AND DATA ANALYSIS/PROCEDURE

4 - Time to Speed The time for the vehicle to reach 64 km/hr (40 mph) will be compared to requirement of 12.0 s threshold, 10.0 s objective.

5 - Timed 1/4 Mile The time for the vehicle to travel 402 m (440 yd) at wide-open throttle

(WOT) will be compared to the requirement of 25 s.

2.4.3 Test Procedures and Data Required

a. General. TOP 2-2-602 (ref 11) will be used as a general guide for determining the speed and acceleration characteristics of each vehicle. Testing will be conducted at GVWR with fans operating normally and all original equipment manufacturer (OEM) accessories powered on. The vehicle tires will be inflated to the manufacturer’s recommended pressures for highway operation. Speed and acceleration testing on level roads will be conducted at the PTA 3-mile straightaway. The PTA test course is a 6.1-km (3.8-mi) long level, hard-surfaced straightaway with banked turnaround loops at each end.

b. Instrumentation. Basic instrumentation will include a GPS-based velocity sensor, a six-axis inertial sensor (X, Y, and Z acceleration and pitch, roll and yaw rate), and a fifth wheel velocity sensor. If deemed necessary, the vehicle controller area network (CAN) bus will be recorded to monitor engine speed and transmission settings. All instrumentation will be calibrated and the data will be recorded using a Dewetron digital data acquisition system.

c. Acceleration.

(1) Prior to conducting acceleration runs, the vehicle will be operated while slowly increasing speed up to the maximum forward velocity or 161 km/hr (100 mph). Throughout operations the operator will note any unfavorable tracking/steering characteristics.

(2) The operator will position the vehicle at a designated starting point at one end of the paved test course and place the vehicle transmission in drive, holding the vehicle stationary with the service brake. The operator will then rapidly release the service brake and apply WOT. The operator will drive the vehicle in a straight line from the stationary position to maximum forward velocity (not to exceed 161 km/hr) at WOT for a maximum distance of 3 km (2 mi). This procedure will be repeated in the opposite direction. A minimum of six acceleration runs will be conducted for each test configuration, with an equal number of runs in each direction to negate any wind or grade effects.

2.4-2

(3) The acceleration time for each test run will be measured from the instant vehicle motion begins. If system-response lag is significant, acceleration time will be measured upon first movement of the accelerator pedal. A calibrated load cell (accuracy ±0.25 percent) mounted on the accelerator pedal will be used to trigger the start of each test run, if required.

Maximum vehicle speed will be defined as the speed limited either by governor actuation or available vehicle power if less than 161 km/hr (100 mph). The final determined maximum vehicle speed will be the average of the maximum speeds obtained at the end of each acceleration test event when a sustained speed has been achieved.

(4) In addition to the maximum vehicle speed, the following data points will be obtained from each acceleration run: times to distances of 18 m (60 ft), 101 m (330 ft), 201 m (660 ft), 305 m (1,000 ft), and 402 m (1,320 ft), speeds at distances of 201 m (660 ft) and 402 m (1,320 ft), and time to speeds of 64 km/hr (40 mph) and 97 km/hr (60 mph).

Vehicle configuration Acceleration data (time versus speed) Times to 18 m (60 ft), 101 m (330 ft), 201 m (660 ft), 305 m (1,000 ft), and 402 m (1,320 ft) Times to 64 km/hr (40 mph) and 97 km/hr (60 mph) Speeds at 201 m (660 ft) and 402 m (1,320 ft)

2.5-1

2.5 STEERING AND HANDLING

2.5.1 Objective

Determine the steering and handling characteristics of the test vehicles.

2.5.2 Criteria and Data Analysis/Procedure

TABLE 2.5-1. CRITERION AND DATA ANALYSIS/PROCEDURE

6 - Double Lane Change The speed at which the vehicle is capable of negotiating a double lane change maneuver on a lane change course conforming to the Statement of Work (SOW) (ref 12), Figure 1, will be compared to the requirement of 64 km/hr (40 mph) threshold, 72 km/hr (45 mph) objective. Any unfavorable handling characteristics will be recorded.

7 - Slalom The speed at which the vehicle is capable of negotiating a slalom maneuver on a slalom course conforming to the SOW, Figure 2, will be compared to the requirement of 32 km/hr (20 mph) threshold, 40 km/hr (25 mph) objective. Any unfavorable handling characteristics will be recorded.

2.5.3 Test Procedures and Data Required

a. Testing will be performed with the vehicles at GVWR.

b. Turning Radius.

(1) Minimum wall-to-wall, curb-to-curb, turning circle, and inside trace diameters will be determined in both turning directions (clockwise (CW) and counterclockwise (CCW)) on a dry, concrete surface. The minimum turning diameters will be determined from the circumferences of circles outlined by the outermost part of the combination’s wheels (curb-to-curb).

(2) Prior to dynamic steering testing, a motion sensor will be mounted as near the vehicle’s CG location as practical to measure vehicle roll, pitch, and yaw rates with an accuracy of ±0.3 deg/sec. The motion sensor also provides lateral, longitudinal, and vertical acceleration data. To measure vehicle speed, the vehicle will be instrumented with a non-contact fifth wheel with an accuracy of ±0.25 mph. The data will be recorded on a Dewesoft digital data acquisition system. In addition to the instrumentation, outriggers will also be installed and used for dynamic steering tests.

2.5-2

c. Double Lane Change/Slalom.

(1) The vehicle will be operated through a double lane change course and a slalom course. The dimensions of the double lane change course will be set in accordance with the SOW, Figure 1, reproduced here as Figure 2.5-1. The dimensions of the slalom course will be set in accordance with the SOW, Figure 2, reproduced here as Figure 2.5-2. The course limits will be defined using conventional traffic pylons. Throughout each lane change maneuver, the operator will attempt to maintain a constant vehicle speed while applying the minimum steering inputs necessary to successfully negotiate the course. The vehicle speed for the initial lane change run through each course will be 32 km/hr (20 mph).

Figure 2.5-1. Double lane change course dimensions.

2.5-3

Figure 2.5-2. Slalom course dimensions.

(2) The speeds for subsequent runs will be increased in small increments until the combination either achieves its maximum speed, can no longer successfully negotiate the course without striking the course pylons, or is considered unstable negotiating the course.

Vehicle wheel liftoff, significant vehicle slide, and tire squeal and smoke are typical indicators of vehicle instability, and subsequent testing at higher vehicle speeds will be suspended.

Observational data Turning radii, m (ft) Maximum attained speeds through lane change course, km/hr (mph) Maximum attained speeds through slalom course, km/hr (mph) Photographs of test setup

2.6-1

2.6 ENDURANCE

2.6.1 Objective

Determine the reliability characteristics of the test vehicles.

2.6.2 Criterion and Data Analysis/Procedure

TABLE 2.6-1. CRITERION AND DATA ANALYSIS/PROCEDURE

8 - Quality The results of endurance testing will be used to determine whether the vehicle meets the 3,218-km (2,000-mi) Operational Mode Summary/Mission Profile (OMS/MP) without an operational mission failure (OMF).

2.6.3 Test Procedures and Data Required

a. TOP 2-2-506A (ref 13) will be used as a guide for conducting course operations.

TOP 1-1-030 (ref 14) will be used as a guide for conducting testing. The vehicles will be payloaded to GVWR.

b. Vehicle data will be recorded on an Advanced Distributed Modular Acquisition System (ADMAS). Vehicle speed and location will be measured through a GPS. A six-axis inertial sensor will be placed near the CG of the vehicle to record the chassis accelerations and angular rates in three dimensions. The ADMAS card will be removed and harvested at the end of each shift by the test item data collector. ADMAS files will be accessible on the Engineering Units Database

(EUDB).

c. Mileage accrued will be measured with the vehicle’s odometer.

d. The vehicle will complete a total of 3,218 km. Total mileage will be in accordance with the DOS OMS/MP. Performance testing may occur before or after endurance testing; all mileage accumulated during performance testing will not contribute towards the 3,218-km endurance requirement. ATC test courses as assigned to the applicable portions of the DOS OMS/MP for this effort are presented in Table 2.6-2.

2.6-2

TABLE 2.6-2. DOS MISSION PROFILE

Terrain Type Test Course

Average Speed Range Cycle 1 Cycle 2 Total km/hr mph km mi km mi km mi

Highway ATEF paved or PTA paved

80-105 50-65 563 350 563 350 1,127 700

Paved roads in traffic/congestion

PTA paved 40-64 25-40 a563 a350 a563 a350 a1,127 a700

Gravel MTA gravel 24-28 15-30 241 150 241 150 483 300 Unimproved/dirt PTA-1 24-28 15-30 241 150 241 150 483 300 aWill be accomplished with complete stops approximately every 5 km (3 mi).

MTA = Munson Test Area.

e. Testing will be conducted in two cycles (table 2.6-3). The test conduct objective will be to complete each test cycle prior to starting the next. Testing will be conducted during inclement weather conditions when they occur; vehicle speed will be adjusted to mitigate safety concerns.

TABLE 2.6-3. MILEAGE SCENARIO

Test Area Course

Cycle 1 Troops

Cycle 2 Stowed Total km mi km mi km mi MTA Gravel 241 150 241 150 483 300

PTA 1 241 150 241 150 483 300

PTA Paved 563 350 563 350 1,127 700 ATEF Paved 563 350 563 350 1,127 700 Total 1,609 1,000 1,609 1,000 3,219 2,000

Note: Individual values may not add to total due to rounding.

f. ATC test course descriptions are identified in TOP 1-1-011A (ref 15). Test course severity is described in TOP 1-1-010 (ref 16).

g. Gravel between courses and paved between courses miles will accumulate as gravel and paved miles, respectively. Paved test miles will be conducted at the end of each payload configuration in order to reduce the amount of excess paved miles operated on each test vehicle.

h. Operating speeds ranges defined will be adhered to during endurance testing.

i. Any failure or maintenance action which occurs during testing will be recorded and documented in a TIR. TIRs will be written in accordance with Department of the Army Pamphlet (DA PAM) 73-1 (ref 17), and will be pre-scored in accordance with maintenance requirement methodology. Each TIR will be scored with one of six options depending on the incident type and, if applicable, failure severity: no test, scheduled maintenance action (SMA), crew correctable maintenance action (CCMA), unscheduled maintenance action (UMA), essential maintenance

2.6-3 action (EMA), or OMF. All TIRs will be available through the Versatile Information Systems Integrated On-Line (VISION) Digital Library System (VDLS). The vehicle odometer and engine hour meter will be used to determine component part life. Manufacturer part numbers, and serial numbers will be used to track frequency of replacement.

(1) Test conduct will be executed in accordance with mission-oriented maintenance and data collection methodology. Testing will be divided into approximately four separate 804-km (500-mi) missions. Failures during testing will be classified in the field by the test officer in accordance with the criterion definition. The maintenance strategy will be as follows:

(a) CCMAs will be performed during the daily PMCS and throughout the simulated mission, as required.

(b) UMAs will be deferred until the next scheduled service or the end of test, as appropriate.

(c) EMAs will be deferred until the completion of the current simulated 804-km mission, and repaired prior to the start of the next mission.

(d) OMFs will be repaired immediately.

(e) SMAs will be performed as prescribed in any applicable maintenance documentation.

(2) Each mission will be transparent of terrain type. Each TIR will contain the mission number along with the time when maintained (during mission, after mission, or postponed).

(3) Executing in accordance with mission oriented maintenance and data collection methodology in a Developmental Test (DT) environment contains several limitations and considerations. Examples of these considerations include, but are not limited to:

(a) Incidents that are difficult to assess, describe, or repair may require troubleshooting during the actual mission to ensure all available data and understanding are being attained.

Troubleshooting may be conducted to develop an understanding of an issue without implementing a repair.

(b) Environmental stewardship may require repairing leaking components.

(c) Safety issues may require repair to mitigate safety hazards for DT operators.

(4) The ATC test officer will assess vehicle readiness prior to proceeding into the next mission. The vehicle readiness assessment will analyze all existing non-corrected faults. If a vehicle is not mission ready, entrance criteria to include all required corrective actions will be established and relayed to maintainers. Information pertinent to the assessment will be documented in mission summary TIRs.

j. TIR block 36 special requirement data:

(1) Mission Number (1-9).

(2) Maintained (during mission, after mission, or postponed).

2.6-4

k. The vehicle will be maintained as follows:

(1) Crew level maintenance tasks will be performed by ATC personnel using basic issue items (BII) tools stowed on the vehicle. Any additional tools required outside of the BII to accomplish the prescribed maintenance action will be documented in the associated TIR and pre-scored accordingly.

(2) All maintenance above the crew level will be performed by field service representatives (FSRs) or ATC mechanics (if a technical manual (TM) and parts are provided).

(3) For each maintenance action required, the total chargeable maintenance time, diagnostic time, man-hours, and level of maintenance (LOM) will be recorded in the associated

TIR.

l. The weight of the vehicle may change throughout testing due to the collection of debris during off-road operations and manufacturer modifications. Periodically, the vehicle will be washed to ensure debris is not deposited on paved surfaces. However, washing may not remove all debris. Any residual debris may increase vehicle weight. Payload will not be removed to adjust for the increase in vehicle weight attributed to the operational environment or manufacturer modifications. The payload items will be documented and weighed at the beginning of the test;

the payload will not be altered for the duration of the test. Vehicles will be washed if required when changing test areas, changing to paved operations, when maintenance warrants, when debris prevents proper PMCS, when a failure warrants (ex. cooling issue, clutch disengagement), or as requested by a test officer. The wash racks are equipped with high volume, low pressure water. The pumps which power the wash rack shut off in two scenarios: if they are starved of water (<172 kPa (25 psi)) or if the hose is kinked (>689 kPa (100 psi)). Therefore, the vehicle is never subjected to pressures exceeding 689 kPa while washing.

m. The following data are required:

Test courses Distance traveled per course, km (mi) Total engine hours Modifications OMF scored TIRs

2.7-1

2.7 FINAL INSPECTION

2.7.1 Objective

Determine the physical condition of the test vehicles at test completion.

2.7.2 Criteria and Data Analysis/Procedure

Specific criteria were not provided.

2.7.3 Test Procedures and Data Required

a. Portions of TOP 2-2-505 will be used as a general guide.

b. Upon completion of testing, all systems will be inspected using the information contained in the appropriate manuals.

c. Each major component will be inspected for physical damage, proper installation or alignment, and functional operability in accordance with TOP 2-2-505. A summary of damage sustained and corrective actions completed will be recorded and photographed. Any faults, failures, incipient malfunctions, or discrepancies will be examined thoroughly to determine the causes or contributing factors.

d. Complete or partial disassembly in specific areas will be accomplished, if warranted, to determine the causes and extent of damage. Prior to disassembly, approval by the test sponsor will be obtained.

e. Photographs will be taken of all damaged areas. The data collected will be reviewed and analyzed to determine the degree of damage and degradation as a result of testing. An assessment will be made of defects (both existing and incipient) to determine whether they are chargeable against the test item as failures.

f. The following data are required:

Description of defects or malfunctions, if any Photographs or measurements indicating abnormal wear, deformation, or damage of components

Item Applicable Source Test Criterion Subtest Remark

A-1

FO

R

O

FFIC

IAL U

SE O

N

LY

1 Test Agency devised, DoS approved

Workmanship shall be of the highest grade consistent with the intention of this specification. Vehicle shall have no evidence of cracks, dents, scratches, burrs, sharp edges, loose parts, foreign matter, or any other evidence of poor workmanship that shall render the vehicle unsuitable/unsafe for the purpose intended. The cab, chassis and bodies shall be designed such that normal vehicle operation does not cause chafing, binding or other damage to any harness, hose, control cable, lanyard, tube or line.

2.1

2 Test Agency devised, DoS approved

All tire and wheel ratings shall conform to the Tire and Rim Association (T&RA) or the European Tyre and Rim Technical Organization (ETRTO) Standards Manual for the vehicle in Operational Configuration and the advertised GAWR at the maximum speed of the vehicle.

2.2

3 Test Agency devised, DoS approved

The vehicle at Operational Configuration shall meet the stopping distance requirements presented in Table II of FMVSS 105.

ABS shall be functional.

2.3

4 Test Agency devised, DoS approved

The vehicle at Operational Configuration shall be capable of accelerating on dry, level hard terrain from 0 to 64 km/hr (40 mph) within 12.0 s threshold, 10.0 s objective.

2.4

5 Test Agency devised, DoS approved

The vehicle at Operational Configuration shall be capable of travelling 402 m (440 yd) at wide-open throttle (WOT) in 25 s threshold.

2.4

6 Test Agency devised, DoS approved

The vehicle in Operational Configuration shall be capable of completing a double lane change maneuver on a lane change course conforming to SOW Figure 1 - Double Lane Change Maneuver Course (First Article Testing - DOS AV Programe 201811-01 (002), at speeds up to 64 km/hr (40 mph) threshold, 72 km/hr (45 mph) objective. Vehicle shall not demonstrate any unfavorable handling characteristics.

2.5

SEC

TIO

N

3. A

PPEN

D

IXES

A

PPEN

D

IX A

. TEST CR

ITER

IA

Item Applicable Source Test Criterion Subtest Remark

A-2

FO

R

O

FFIC

IAL U

SE O

N

LY

7 Test Agency devised, DoS approved

The vehicle in Operational Configuration shall be capable of completing a slalom maneuver on a slalom course conforming to SOW Figure 2 - Slalom Maneuver Course (First Article Testing - DOS AV Programe 201811-01 (002), at speeds up to 32 km/hr (20 mph) threshold, 40 km/hr (25 mph) objective. Vehicle shall not demonstrate any unfavorable handling characteristics.

2.5

8 Test Agency devised, DoS approved

The vehicle shall meet the 3,219-km (2,000-mi) OMS/MP without an operational mission failure, defined as an event that results in the loss of a mission essential function that reduces its utility to the point that it is deemed ineffective in its role (unable to be remedied at the crew level with tools or equipment which are included with the base vehicle where provisions are in place for adequate stowage).

2.6

B-1

APPENDIX B. TEST SCHEDULE

Activity Duration, days Initial Inspection Physical Characteristics Braking Speed and Acceleration Steering and Handling Endurance Final Inspection

This is another option…

Activity Date, 19 Duration, days Start End Initial Inspection Physical Characteristics Braking Speed and Acceleration Steering and Handling Endurance Final Inspection

C-1

APPENDIX C. INFORMAL COORDINATION

This test plan has been coordinated with the following agencies:

Director U.S. Army Evaluation Center ATTN: TEEC-MS-T (Mr. Martin Bindel) 2202 Aberdeen Boulevard Aberdeen Proving Ground, MD 21005-5001

U.S. Department of State ATTN: Ms. Sarah Gregory 7952 Cluny Court Springfield, VA 22153-2810

D-1

APPENDIX D. REFERENCES

1. ATEC Decision Support System (ADSS) Project Established, ATEC, TEEC-MS-T, 11 December 2018, subject: Automotive Test of the U.S. Department of State (DOS) Armored Vehicles, ATEC Project No. 2019-DT-ATC-TWVLF-H1420.

2. TOP 2-2-505, Inspection and Preliminary Operation of Vehicles, 4 February 1987.

3. TOP 2-2-500, Vehicle Characteristics, 14 February 2008.

4. TOP 2-2-801, Weight Distribution and Ground Pressure (Wheeled and Tracked Vehicles), 26 September 2006.

5. 2019 Year Book, The Tire and Rim Association, Inc.

6. TOP 2-2-800, Center of Gravity, 26 September 2006.

7. SAE J2180, A Tilt Table Procedure for Measuring the Static Rollover Threshold for Heavy

Trucks, 17 May 2011.

8. FMVSS 105, Hydraulic and Electric Brake Systems, 30 June 2005.

9. TOP 2-2-608, Braking, Wheeled Vehicles, 20 May 2008.

10. SAE J299, Stopping Distance Test Procedure, 30 January 2009.

11. TOP 2 2-602, Acceleration; Maximum and Minimum Speeds, 28 January 1981.

12. Department of State Armored Vehicle Scope of Work, 11 January 2018.

13. TOP 2-2-506A, Wheeled and Tracked Vehicle Endurance Testing, 2 October 2014.

14. TOP 1-1-030, RAM-D and ILS Analysis, 8 September 2008.

15. TOP 1-1-011A, Vehicle Test Facilities at Aberdeen Test Center and Yuma Test Center, 27 February, 2012.

16. TOP 1-1-010, Vehicle Test Course Severity (Surface Roughness), Change 1, 4 January 2012.

17. DA PAM 73-1, Test and Evaluation in Support of Systems Acquisition, 30 May 2003.

E-1

APPENDIX E. ABBREVIATIONS

ABS = antilock braking system ADMAS = Advanced Distributed Modular Acquisition System APG = Aberdeen Proving Ground ATC = U.S. Army Aberdeen Test Center ATEC = U.S. Army Test and Evaluation Command ATEF = Automotive Technology Evaluation Facility AV = armored vehicle BII = basic issue items CAN = controller area network CCMA = crew correctable maintenance action CCW = counterclockwise CG = center of gravity CW = clockwise DA PAM = Department of the Army Pamphlet DOS = U.S. Department of State DT = Developmental Test EMA = essential maintenance action ETRTO = European Tyre and Rim Technical Organization EUDB = Engineering Units Database FMVSS = Federal Motor Vehicle Safety Standard FSR = field service representative GAWR = gross axle weight rating GPS = global positioning system GVWR = gross vehicle weight rating LOM = level of maintenance MTA = Munson Test Area NIST = National Institute of Standards and Technology OEM = original equipment manufacturer OMF = operational mission failure OMS/MP = Operational Mode Summary/Mission Profile PMCS = preventive maintenance checks and services PTA = Perryman Test Area SAE = Society of Automotive Engineers SMA = scheduled maintenance action SOW = Statement of Work T&RA = Tire and Rim Association TIIN = test item identification number TIR = Test Incident Report TM = technical manual TOP = Test Operations Procedure UMA = unscheduled maintenance action VDLS = VISION Digital Library System VISION = Versatile Information Systems Integrated On-Line WOT = wide-open throttle DRAFT

Secondary distribution is controlled by the U.S. Department of State.

F-1

APPENDIX F. DISTRIBUTION LIST

ATEC Project No. 2019-DT-ATC-TWVLF-H1420

Note: A copy of this document has been posted on the Versatile Information Systems Integrated On-Line (VISION) Digital Library (VDL), https://vdls.atc.army.mil.

Test Final Addressee Plans Reports

Director U.S. Army Evaluation Center ATTN: TEEC-MS-M (Mr. Martin Bindel) 1 1 2202 Aberdeen Boulevard Aberdeen Proving Ground, MD 21005-5001

U.S. Department of State ATTN: Ms. Sarah Gregory 1 1 7952 Cluny Court Springfield, VA 22153-2810

Commander U.S. Army Aberdeen Test Center ATTN: TEAT-ADV (Mr. Donald Hirt) 1 1

TEAT-CSH 1 1

TEAT-POT 1 1

400 Colleran Road Aberdeen Proving Ground, MD 21005-5059