50T NNSY LHS Spec C400 CURRENT redacted.pdf

EQUIPMENT SPECIFICATION

FOR

LIGHT WEIGHT WIDE APERTURE ARRAY HANDLING

SYSTEM

April 19, 2019

Prepared By:

NORFOLK NAVAL SHIPYARD

Strategic Planning Branch / Mechanical Engineer

Norfolk Naval Shipyard Rob Steiner, Code 713

Strategic Planning Branch / Electrical Engineer

Norfolk Naval Shipyard Chris Moore, Code 713

TABLE OF CONTENTS

i

1.0 SPECIFICATION

1.1 SCOPE

2.0 APPLICABLE DOCUMENTS

3.0 NOTES

3.1 DOMESTIC MAKE

3.2 SHORT TONS

3.3 ENGLISH DOCUMENTATION

4.0 PURPOSE

4.1 PRIMARY USE OF THE LHS

4.2 SECONDARY USE OF THE LHS

5.0 GENERAL REQUIREMENTS

5.1 DESCRIPTION OF COMPONENTS OF THE LHS

5.1.1 SELF-PROPELLED FLAT DECK BASE

5.1.2 LHS MODULAR FIXTURE

5.2 USAGE FOR HANDLING LWWAA COMPONENTS

5.3 QUANTITIES

5.4 PHYSICAL CHARACTERISTICS

5.5 OPERATING ENVIRONMENT

5.5.1 SHIPYARD CONDITIONS

5.5.2 WEATHER

5.5.3 ELECTROMAGNETIC INTERFERENCE (EMI)

5.5.4 GRADE

5.6 MATERIALS

5.6.1 MATERIAL SAFETY DATA SHEETS (MSDS)

5.6.2 OIL ABSORBSION

5.6.3 COMMERCIAL OFF-THE-SHELF

5.7 DEVIATIONS

5.8 EXCEPTIONS

5.9 RESPONSIBILITY FOR ERRORS

6.0 DESIGN

6.1 GENERAL

6.1.1 APPLICABLE DESIGN CODES

6.1.2 SAFETY AND HEALTH REQUIREMENTS

6.1.3 6.1.3.1

AUDIBLE NOISE LEVELS

EXCESSIVE NOISE

6.1.4 USE OF POLYCHLORINATED BIPHENYL (PCB)

6.1.5 USE OF MERCURY

6.1.6 6.1.7

USE OF ASBESTOS

USE OF LEAD

6.1.8 ENVIRONMENTAL PROTECTION

6.2 GEARS

6.3 CONSTRUCTION

6.3.1 CASTINGS AND FORGINGS

6.3.2 WELDING, BRAZING OR SOLDERING

6.3.2.1 SOLDERING

6.3.2.1.1 CLEANING

ii

6.3.2.1.2 FLUX AND CLEANING AGENTS

6.3.3 FASTENERS AND LOCKING DEVICES

6.3.3.1 CRITICAL FASTENERS

6.3.3.2 6.3.3.3

MISCELLANEOUS FASTENERS

LOCKING FASTENER INDEX

6.3.3.4 GRADE IDENTIFICATION

6.3.3.5 INTERNALLY THREADED CONNECTIONS

6.3.4 SURFACES

6.3.4.1 6.3.4.1.1

PAINTING

COLOR SCHEME

6.3.4.2 ALUMINUM SURFACES

6.3.4.3 FERROUS PARTS

6.3.4.4 DISSIMILAR METALS

6.4 STRUCTURAL COMPONENTS

6.4.1 STRUCTURAL MEMBERS

6.4.2 WELDING STANDARDS FOR STRUCTURAL MEMBERS

6.4.3 SPECIFIC STRUCTURAL REQUIREMENTS FOR SELF-

PROPELLED BASE

6.4.3.1 AREA OF DECK

6.4.3.2 CONNECTION TO LOAD / FIXTURING

6.4.3.3 IDENTIFICATION OF LOAD SUPPORT AREAS

6.4.3.4 PROTECTION OF OPENINGS ON TOPSIDE OF SELF-

PROPELLED BASE

6.4.4 SPECIFIC STRUCTURAL REQUIREMENTS FOR LHS

MODULAR FIXTURE

6.4.4.1 CONNECTION TO SELF-PROPELLED BASE

6.5 LIFTING/HANDLING

6.5.1 LIFTING BY CRANE

6.5.2 LIFTING POINTS

6.5.2.1 LOCATION OF LIFTING POINTS

6.5.2.2 PROTECTION OF LIFTING POINTS

6.5.2.3 FACTOR OF SAFETY OF LIFTING POINTS

6.5.2.4 DEPTH OF TAPPED HOLES

6.5.2.5 LIFTING POINT IDENTIFICATION

6.5.2.6 IDENTIFICATION OF LHS COMPONENT WEIGHT

6.5.2.7 LIFTING DIAGRAM

6.6 SELF-PROPELLED BASE DETAILED REQUIREMENTS

6.6.1 PROPULSION

6.6.1.1 PROPANE INTERNAL COMBUSTION ENGINE

6.6.1.2 COOLING SYSTEM

6.6.1.3 AIR FILTERING

6.6.1.4 NOISE CONTROL

6.6.1.5 PROPANE TANKS

6.6.1.6 POWERPLANT START-UP

6.6.2 SECONDARY SOURCE OF MOTIVE POWER

6.6.2.1 UMBILICAL CORD

iii

6.6.3 EMERGENCY STOPS

6.7 LIFT SYSTEM – SELF-PROPELLED BASE

6.7.1 6.7.1.1

LOAD CAPACITY

VARIABLE GEOMETRY COMPONENTS

6.7.2 METHOD OF LIFT

6.7.3 HYDRAULIC LIFT SYSTEMS

6.7.4 TRAVEL AT SUSPENSION LIMITS

6.7.5 RATE OF LIFT

6.7.6 NORMAL MODE OF LIFTING

6.6.4.7 PITCH AND ROLL

6.7.8 LOAD INDICATION

6.8 MAINTAINING LOAD POSITION – SELF-PROPELLED BASE

6.8.1 HOLDING BRAKES

6.8.2 ELECTRONIC BRAKING

6.8.3 6.8.4

MECHANICAL LOAD SUPPORT

EMERGENCY LOWERING

6.9 HYDRAULIC SYSTEM

6.9.1 HYDRAULIC SYSTEM CAPACITY

6.9.2 HYDRAULIC SYSTEM WARM-UP

6.9.3 HYDRAULIC SYSTEM PRESSURE

6.9.4 HYDRAULIC FLUID

6.9.5 HYDRAULIC SYSTEM COMPONENTS

6.9.5.1 6.9.5.2

PRESSURE GAUGES

SOFT GOODS INDEX

6.9.5.3 CHECK VALVES

6.9.5.4 HYDRAULIC CYLINDERS

6.9.5.5 RESERVOIR

6.9.5.5.1 RESERVOIR FLUID LEVEL INDICATION

6.9.5.5.2 RESERVOIR VENT

6.9.5.5.3 RESERVOIR ACCESS

6.9.5.5.5 LOCATION OF PRESSURE TEST POINTS

6.9.5.5.6 IDENTIFICATION OF HYDRAULIC SYSTEM COMPONENTS

6.9.5.7 PRESSURE TRANSDUCERS

6.9.6 FILTRATION

6.9.6.1 FILTRATION STANDARD

6.9.6.2 FLUID SAMPLING

6.9.6.3 FILTER ACCESSIBILITY

6.9.6.4 FILTER COUNTRY OF ORIGIN

6.9.7 6.10 6.10.1 6.10.2

HYDRAULIC ENERGY LOCKOUT

HYDRAULIC SYSTEM IDENTIFICATION AND MARKINGS

PIPING IDENTIFICATION

NUMBERING

6.10.3 HYDRAULIC VALVES AND COMPONENTS

6.10.3.1 LABELS AND TAGS

6.10.3.2 LABEL AND TAG LOCATION

6.10.3.3 IDENTIFICATION OF SOLENOIDS

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6.11 LUBRICATION

6.11.1 DOMESTIC COMMERCIAL LUBRICANTS

6.11.2 LUBRICATION POINTS

6.11.3 LUBRICATION CHART OR PLATE

6.12 ELECTRICAL SYSTEM

6.12.1 ELECTRICAL EQUIPMENT

6.12.2 ELECTRIC POWER DISCONNECT

6.12.3 ELECTRICAL CONNECTIONS

6.12.4 GROUNDING

6.12.5 SOLID-STATE COMPONENTS

6.12.6 GENERATOR / ALTERNATOR

6.12.7 6.12.7.1

BATTERIES

BATTERY MAINTENANCE CHARGER

6.12.8 WIRING HARNESS

6.12.9 WIRING CONDUIT

6.12.10 CIRCUIT PROTECTION

6.12.11 HOTEL (EXTERNAL) POWER SUPPLY & CONNECTIONS

6.12.12 EXTERNAL POWER CONNECTIONS

6.12.13 MISCELLANEOUS ELECTRICAL DEVICES

6.12.14 INTERNAL CONNECTIONS

6.12.15 EMERGENCY STOP BUTTONS

6.12.16 EMERGENCY STOP RESET

6.12.17 ELECTRONIC CONTROL SYSTEMS

6.12.17.1 ELECTRICAL CONTROL SYSTEM STANDARDS

6.12.17.2 CIRCUIT BOARDS

6.12.17.3 PROGRAMMABLE LOGIC CONTROLLERS.

6.12.17.4 INACCESSABLE ELECTRONIC COMPONENTS

6.12.17.5 INTERNALLY GENERATED ELECTROMAGNETIC

INTERFERENCE

6.12.17.6 COMPUTER INTERFACE

6.12.18 ELECTRICAL ENCLOSURE ENVIRONMENTAL CONTROLS

6.12.19 VIBRATION ISOLATION

6.12.20 ELECTRONIC EQUIPMENT ACCESS

6.12.21 ELECTRICAL ENERGY LOCKOUT

6.12.22 DETAILS OF ELECTRONIC COMPONENTS FOR

CONTRACTOR’S PROPOSAL

6.12.23 WIRING IDENTIFICATION

6.12.24 TERMINAL MARKING

6.12.25 TEST POINT LABELING

6.12.26 NUMBERING

6.12.27 COMMONALITY OF WIRING

6.12.28 6.12.29

COMPONENT IDENTIFICATION

ELECTRICAL ASSEMBLY

6.13 ELECTRIC MOTORS

6.13.1 MOTORS

6.13.2 OVERLOAD PROTECTION

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6.14 6.14.1

CONTROL PANELS, INSTRUMENTS, AND PLATES

PROTECTIVE FUSES

6.14.1.1 COORDINATION STUDY

6.14.2 PHYSICAL CHARACTERISTICS OF CONTROLS AND

INDICATORS

6.14.2.1 INDICATORS / INSTRUMENTATION

6.14.2.2 REQUIRED INSTRUMENTATION

6.14.2.3 INDICATION OF PUMP DISCHARGE

6.14.2.4 MULTI-FUNCTION DISPLAY

6.14.2.5 ABNORMAL OPERATION INDICATION

6.14.3 CONTROLS

6.14.3.1 EASE OF OPERATION

6.14.3.2 CONTROL STATION

6.14.3.3 DEAD MAN FEATURE

6.14.3.4 HANDHELD CONTROLLER

6.15 STEERING

6.15.1 ELECTRONICALLY CONTROLLED STEERING

6.15.2 STEERING MODES

6.15.2.1 NORMAL STEERING MODE

6.15.2.2 DIAGONAL STEERING MODE

6.15.2.3 TRANSVERSE STEERING MODE

6.15.2.4 DEFINED RADIUS STEERING MODE

6.16 DRIVE MODES

6.16.1 NORMAL MODE

6.16.2 25% SPEED MODE

6.16.3 JOG MODE

6.16.4 CHANGE OF DRIVE DIRECTION

6.17 POSITIONAL ACCURACY

6.18 CONCURRENT OPERATION

6.18.1 RELATIVE POSITION

6.18.2 OVERTORQUE LIMITATION

6.19 INTERCHANGEABILITY OF SELF-PROPELLED BASES

6.20 TIRES AND WHEELS

6.20.1 SOLID WHEELS

6.20.2 WHEEL LOADING

6.21 MAINTAINABILITY

6.22 EXTERNAL MARKINGS

6.22.1 UNIT INDENTIFICATION

6.22.2 6.23 6.24 6.25 6.26 6.27

DIRECTIONAL MARKING

CAUTION – WARNING PLATES

MAJOR ASSEMBLY IDENTIFICATION PLATES

PART IDENTIFICATION

WORKMANSHIP

NEW DEVELOPMENTS

7.0 LOGISITICS AND TECHNICAL DOCUMENTATION

7.1 TECHNICAL MANUALS

vi

7.1.1 INCLUDED DOCUMENTATION

7.1.2 MANUALS FORMAT

7.2 DRAWINGS

7.2.1 DRAWING DETAIL

7.2.2 7.2.2.1

PROPRIETARY DATA

PROPRIETARY DATA/SOFTWARE ESCROW

7.2.3 7.2.4

COMPUTER SOFTWARE

DRAWING FORMAT

7.3 PREVENTATIVE MAINTENANCE SYSTEM

7.3.1 7.3.1.1

SPECIAL TOOLING

COVERS

7.3.2 SAFETY PRECAUTIONS

7.3.3 SPARE PARTS

7.3.4 PRESERVATION, PACKING & PACKAGING REQUIREMENTS.

7.3.5 SPECIALIZED EQUIPMENT OR TOOLING

8.0 TESTING

8.1 TEST RESPONSIBILITIES

8.1.1 MATERIALS, MANPOWER, AND FACILITIES

8.1.2 RESOLUTION OF FAILURES

8.2 HYDRAULIC SYSTEM CLEANING AND TESTING

8.2.1 SYSTEM CLEANLINESS

8.2.2 HYDROSTATIC TEST

8.2.3 MECHANICAL JOINTS

8.3 OPERATIONAL TESTING

8.3.1 TEST APPROVAL

8.3.2 NOTIFICATION OF TESTING

8.3.3 LOAD TEST

8.3.3.1 TEST LOADS

8.3.4 TEST OF CONCURRENT OPERATION

8.3.5 AUDIBLE NOISE TEST

8.3.6 OPERATIONAL TEST

8.3.7 AMBIENT CONDITIONS

8.3.8 RELATION TO EXTREMES OF OPERATING REQUIRMENTS

8.3.9 EXPECTATIONS

8.3.10 8.3.10.1

POST SHIPMENT TESTING

SITE ACCEPTANCE TEST SUPPORT

9.0 PROCURMENT QUALITY ASSURANCE, INSPECTION, AND

ACCEPTANCE

9.1 EXAMINATION AT DESTINATION

10.0 10.1

TECHNICAL SUPPORT

SERVICABLE COMPONENTS

11 ACCEPTANCE REQUIREMENTS

12.0 WARRANTY

13.0 TRAINING

13.1 MAINTENANCE PERSONNEL (MECHANICAL / HYDRAULIC)

vii

13.1.1 MAINTENANCE PERSONNEL (MECHANICAL / HYDRAULIC)

TRAINING SCHEDULE

13.2 MAINTENANCE PERSONNEL (ELECTRICAL / ELECTRONIC)...

13.2.1 MAINTENANCE PERSONNEL (ELECTRICAL / ELECTRONIC)

TRAINING SCHEDULE

13.3 OPERATOR TRAINING

13.3.1 OPERATOR TRAINING SCHEDULE

13.4 POST DELIVERY TRAINING

14.0 SPECIAL DELIVERY INSTRUCTIONS

15.0 ON-SITE REGULATIONS

15.1 CONTRACTOR ON-SITE PERSONNEL

15.2 STORAGE AND DEBRIS

LIST OF FIGURES

FIGURE 1

SELF-PROPELLED BASE ENVELOPE

FIGURE 2

LHS MODULAR FIXTURE ENVELOPE

FIGURE 3

MAJOR COMPONENTS OF THE LWWAA HANDLED BY THE LHS…… 6

FIGURE 4

ARRANGEMENT OF LWWAA ON HULL IN RELATION TO LHS……….. 16

1.0 SPECIFICATION

1.1 SCOPE – This specification is for the purchase of a specialized self - propelled Light Weight Wide Aperture Array Handling System (LHS). The system is to be used for transporting and positioning components of the Light Weight Wide Aperture Array (LWWAA) during removal and reinstallation. The system shall be complete and operational with all components, accessories, parts, and services specified herein.

2.0 APPLICABLE DOCUMENTS – The following documents form a part of this specification, to the extent specified herein. Unless otherwise indicated, the issue in effect on date of solicitation shall apply.

TITLE 29, CODE OF FEDERAL REGULATIONS, CHAPTER XVII, PART 1910 –

OCCUPATIONAL SAFETY AND HEALTH STANDARDS

(Address application for copies to Superintendent of Documents, Government Printing Office, Washington, DC 20402)

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

(Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

AMERICAN WELDING SOCIETY (AWS)

(Address application for copies to the American Welding Society, 550 N.W. LeJeune Road, Miami, Florida 33126)

AMERICAN GEAR MANUFACTURER’S ASSOCIATION (AGMA)

(Address application for copies to the American Gear Manufacturer’s Association, 1901 Fort Myers Drive, Suite 1000, Arlington, VA 22209)

AMERICAN SOCIETY FOR MECHANICAL ENGINEERS (ASME)

SECTION VIII – BOILER AND PRESSURE VESSEL CODE

(Address application for copies to the American Society of Mechanical Engineers, 345 East 47th Street, 8th Floor, New York, NY 10017)

FEDERAL COMMUNICATIONS COMMISSION RULES AND REGULATIONS

VOLUME II, PART 18 – INDUSTRIAL, SCIENTIFIC AND MEDICAL

EQUIPMENT

(Address application for copies to Superintendent of Documents, Government Printing Office, Washington, DC 20402)

NATIONAL ELECTRICAL MANUFACTURER’S ASSOCIATION (NEMA)

ICS – INDUSTRIAL CONTROLS AND SYSTEMS

MGI – MOTORS AND GENERATORS

(Address application for copies to National Electrical Manufacturer’s Association, 1300 N. 17th St., Suite 1847, Rosslyn, VA 22209)

ELECTRONIC INDUSTRIES ASSOCIATION (EIA) STANDARDS

(Address application for copies to the Electronic Industries Association, Engineering Dept., 2500 Wilson Blvd., Arlington, VA 22201-3834)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NATIONAL ELECTRICAL CODE NFPA 70

OVENS AND FURNACES NFPA 86

ELECTRICAL STANDARDS FOR INDUSTRIAL MACHINERY NFPA 79

(Address application for copies to the National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

(Standard copies can be located on the internet at:

http://www.astm.org/cgibin/SoftCart.exe/NEWSITE_JAVASCRIPT/index.shtml?L+mysto re+rreq8222+1197662301)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

(Address application for copies to SAE Automotive Headquarters, 755 W. Big Beaver, Suite 1600, Troy MI 48084 USA)

FEDERAL STANDARDS

(Address application for copies to Headquarters, Superintendent of Documents, Government Printing Office, Washington D.C. 20402)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

(Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

3.0 NOTES

3.1 DOMESTIC MAKE – Domestic make refers to equipment available from United States (U.S.) manufacturers.

3.2 SHORT TONS – Loads, where specified in tons, are in short tons (1 short ton = 2000 lbs)

3.3 ENGLISH DOCUMENTATION – All documentation and equipment identification shall be provided in the English language.

4.0 PURPOSE – The purpose of this specification is to define the requirements for a LWWAA handling system, intended to be used in a naval shipyard dry dock, for the removal and reinstallation of LWWAA handling components off of / onto a submarine hull. This specification shall be used in developing the final design and purchasing proposals.

4.1 PRIMARY USE OF THE LHS – The primary use for the LHS will be to transport, support, capture, lift, and lower the LWWAA components to and from their position on the hull of the submarine, while providing a work platform from which personnel can safely access the fasteners holding the LWWAA components in place. The LHS will be lifted by crane and lowered onto the floor of a dry dock. Once located in the dry dock, the self-propelled LHS will be driven into position below an LWWAA, to perform the aforementioned operations. Additionally, the LHS will allow for LWWAA components to be moved to locations in the dry dock where the components can be lifted into / out of the dock via crane.

4.2 SECONDARY USE OF THE LHS – The secondary use for the LHS will be to position and transport outsized (or difficult to access) submarine components and loads to / from locations in the dry dock where they can be lifted into / out of the dock via crane. Any additional fixtures needed to handle these components will not be procured under this specification.

5.0 GENERAL REQUIREMENTS

5.1 DESCRIPTION OF COMPONENTS OF THE LHS – The handling system will be comprised of self-propelled flat deck base and a modular fixture that will engage the LWWAA. The modular fixture is included as part of this contact and built per NAVSEA Drawing No.8357284.

5.1.1 SELF-PROPELLED FLAT DECK BASE – Each self-propelled flat deck base will have the ability to be operated individually or in concurrent operation, by a single operator using a single controller. Individual self-propelled flat deck bases (or units operating concurrently) shall have the capability to precisely and accurately lift, transport and control a load within the parameters stipulated in Section 6. Each self-propelled flat deck base will possess a high degree of maneuverability, whether being used independently or in concurrent operation. While being operated independently or concurrently, each self-propelled flat deck base will have the ability to independently and automatically control a load’s position by adjusting to variations in the surface over which it rolls, while imparting low contact pressures to those underlying surfaces. The unit performance will meet all other design parameters stipulated herein.

5.1.2 LHS MODULAR FIXTURE – Each modular fixture will be mechanically fastened to the deck of a self-propelled base with four 2”-4.5UNC-2Ax4” hex head cap screws. The cap screw will go thought the 2” diameter holes located at the four corners of the fixture as shown below in Figure 1. While installed on the self-propelled base, the fixture will support the LWWAA components while allowing for fine adjustment of their position.

The fixture will be manually operated where practical and will utilize minimal automation, while employing a high degree of precision. A portion of the fixture will be detachable from the fixture assembly and will function as a lifting fixture to allow the LWWAA components to be lifted into and out of the dry dock. The modular fixture’s dimensions will be limited to the space envelope provided in Figure 2. Each modular fixture shall be completely interchangeable with any of the self-propelled bases.

Figure 1 – Modular Fixture Base

5.2 USAGE FOR HANDLING LWWAA COMPONENTS – The LHS shall:

a) Interface with the four major components of the LWWAA (Refer to Para 6.7.1.1).

b) Support the weight of the component loads, the associated handling fixtures, and the workers performing installation / removal operations.

c) Align and position the LWWAA components into position on the boat’s hull.

d) Provide motive power to move LWWAA components within the dry dock at controlled speed, while being able to fine-adjust a component’s position parallel to the ship’s axis, vertically, and athwartship.

e) Integrate supporting features for transporting the Toepiece Assemblies (TA) and the Transition Covers (TC)’s. Lifting and handling of the TA and the TC’s will be accomplished using shipyard rigging independent of the LHS and is not covered by this specification.

5.3 QUANTITIES – The LHS will consist of one self-propelled base.

5.4 PHYSICAL CHARACTERISTICS – The following physical characteristics of the LHS are considered to be non-deviational by the Government. Prior to proceeding with any change in these areas the Contractor shall submit the proposed change to the Government, in writing, for Government’s written approval.

a) The self-propelled bases’ overall minimum/maximum envelope shall be as shown in Figure 3.

b) The self-propelled bases, in the fully lowered position, unloaded, shall be no higher than 27 inches. See Figure 3.

c) The self-propelled bases, in the fully raised position, unloaded, shall be no less than 33 inches. See Figure 3.

d) The LHS modular fixtures shall operate within the dimensions shown in Figure 2.

Figure 2 – LHS Modular Fixture Envelope

Figure 3 – Self Propelled Base Envelope

16.5’

5.5 OPERATING ENVIRONMENT

5.5.1 SHIPYARD CONDITIONS – The LHS shall be capable of functioning in a shipyard outdoor environment. Shipyard environments include dirt/grit, high humidity, exposure to weather, and exposure to salt spray. Materials, coatings, and design shall be suitable to protect bearings, hydraulic systems, electric systems, controls, gauges, mechanisms, and structures. All equipment susceptible to damage from particulate matter such as abrasive grit, weld spatter, metallic particles, and salt water spray shall be protected by appropriate enclosures. Such enclosures shall not interfere with the normal operation of the system.

5.5.2 WEATHER – The transport system shall be designed to operate as specified under the following weather conditions:

a) Ambient air temperature ranges 0°F to +110°F (thermal radiation heating of self-propelled base components is to be considered).

b) Salt air atmosphere (100% humidity).

c) Periodic rain, snow and icing.

d) Wind velocity 25 mph from any direction

5.5.3 ELECTROMAGNETIC INTERFERENCE (EMI) – A shipyard’s environment may contain strong fixed and intermittent electromagnetic signals. The LHS shall be protected against electromagnetic interference. Protection from LHS equipment-generated voltage and current surges as well as from atmospherically generated electrical disturbances (including interference level EMI from high frequency arc welding, communication transceivers, etc.) will be part of the equipment.

5.5.4 GRADE – Whether operating independently or concurrently, the LHS shall be able to perform all functions specified up to a maximum grade of 4%.

5.6 MATERIALS

5.6.1 MATERIAL SAFETY DATA SHEETS (MSDS) – All hazardous materials, fluids, coatings, sealants, thread lockers, lubricants, etc. and their latest Material Safety Data Sheets (MSDS), shall be identified and provided to Government for an Environment, Safety and Occupational Health (ESOH) compliance review.

5.6.2 OIL ABSORBSION – Use of any material with a tendency to absorb oil and become a fire hazard (e.g. open cell foams) shall be minimized when used in areas of the machine subject to high heat or the potential for electrical arcing.

5.6.3 COMMERCIAL OFF-THE-SHELF – Within the LHS, commercial off-the-shelf (COTS) parts shall be used whenever practical. COTS components shall be installed and used as directed by the part original equipment manufacturer (OEM). Where deviation from OEM installation and/or use instructions is necessary, written approval from the OEM or the Government shall be obtained. Written OEM approval for any

COTS used against part OEM installation and/or use instructions shall be submitted to the Government prior to the commencement of work. The Vendor shall not assume ownership of any COTS components in which they do not own the rights.

5.7 DEVIATIONS – There shall be no deviations from issued drawings and submitted data without prior written approval of the Government.

5.8 EXCEPTIONS – If the Contractor takes exception to part or parts of this specification, he shall so designate in writing as part of his technical proposal.

5.9 RESPONSIBILITY FOR ERRORS – The Contractor shall be responsible for all errors in detailing and assembly of the equipment.

6.0 DESIGN

6.1 GENERAL – The equipment shall be new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. The equipment shall be of the manufacturer's current field proven design, representative of equipment whose design, capacity and performance characteristics, having been proven through actual field application, are substantially the same as those required of the equipment specified herein.

6.1.1 APPLICABLE DESIGN CODES – The Contractor shall provide a listing of standards invoked for design and manufacture in their plant or in their suppliers’ plants.

The applicable issue shall be the latest utilized by the Contractor in the regular production of self-propelled bases. Copies of other than United States Standards cited shall be provided as part of the Contractor’s technical proposal. English language versions are required. Standards shall be provided for the following:

a) Safety

b) Structural members

c) Welding

d) Electrical system

e) Electronic control system

f) Hydraulic system

g) Gearing

h) Threaded parts and fasteners

6.1.2 SAFETY AND HEALTH REQUIREMENTS – Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. This shall include belting, flywheels and fan blades, even where nominally covered by a general engine compartment cover. 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 1910), General Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other Sections of this specification.

The design and manufacture shall be in accordance with all applicable ANSI safety standards.

6.1.3 AUDIBLE NOISE LEVELS – Audible noise emitted by the equipment shall not exceed 84 dB at the operator's work position, nor at any other point at a distance of 3 feet from the equipment under all operating and service conditions. Noise shall be measured on the "A" weighted scale of a standard sound level meter. Measurements shall be taken at the operator's work position and at each side and end of the equipment. For each measurement, the microphone shall be located on a straight line perpendicular to the surface or corner being measured. The height shall correspond to the point of highest noise level emitted from the surface or corner at the location and distance from the equipment specified herein.

6.1.3.1 EXCESSIVE NOISE - In the event that audible noise levels cannot be maintained below the limits specified in 6.1.3, the machine(s) shall be placarded with requirements to wear hearing protection during operation. Signage shall be approved in writing by the Government prior to installation.

6.1.4 USE OF POLYCHLORINATED BIPHENYL (PCB) – The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

6.1.5 USE OF MERCURY – The equipment shall not contain mercury or mercury compounds, nor shall it be exposed to free mercury during manufacture.

6.1.6 USE OF ASBESTOS – The use of asbestos and materials containing asbestos on or in the furnished equipment is prohibited.

6.1.7 USE OF LEAD - The use of lead and materials containing lead on or in the furnished equipment is prohibited.

6.1.8 ENVIRONMENTAL PROTECTION – The equipment shall not emit materials hazardous to the ecological system, as prescribed by federal, state and local statutes in effect at point of installation, under the operating, service, transportation and storage conditions described herein.

6.2 GEARS – Gears used in the machine and its components shall be machined in either the standard or metric system. Gears shall meet the requirements of ANSI/AGMA 6013, 6034, or 6035. The conversion factors and methods specified in ASTM SI10-2002 shall be used for conversion of metric units (SI) to U.S. Customary System of Units (US) for comparison purposes.

6.3 CONSTRUCTION – The equipment shall be constructed of parts that are new, without defects and free of repair. The equipment shall be complete. When connected to the specified utilities, it shall be capable of any operation for which it is being purchased. The equipment shall be devoid of any defects or characteristics that will preclude conformance with any of the requirements herein.

6.3.1 CASTING AND FORGINGS – Castings and forgings shall be free from defects, scale and mismatching. Processes such as welding, peening, plugging, or filling with cold solders or metallic pastes shall not be used on castings or forgings for reclaiming any parts of the equipment.

6.3.2 WELDING, BRAZING OR SOLDERING – Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design.

These operations shall not be employed as repair measures for defective parts.

6.3.2.1 SOLDERING – Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment.

6.3.2.1.1 CLEANING – Any loose, spattered solder, flux, metal chips, insulation scrap or other foreign material shall be removed from the equipment.

6.3.2.1.2 FLUX AND CLEANING AGENTS – Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections.

6.3.3 FASTENERS AND LOCKING DEVICES – Screws, pins, bolts, nuts, washers, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration. Use of anaerobic compound is permissible. Where anaerobic compound is not used, anti-seize compound or other suitable material shall be applied to prevent corrosion/galling of fasteners.

6.3.3.1 CRITICAL FASTENERS – All fasteners for operational critical components (e.g.

load bearing joints) shall use ASTM A325, ASTM A490, SAE J429 (Grade 5 or Grade 8) cap screws and shall be equipped with a locking (or self-locking) feature to prevent vibration induced loosening. Use of anaerobic compound is permissible. However, if a component manufacturer requires a fastener with a higher grade, then the higher grade will be required by this specification.

6.3.3.2 LOCKING FASTENER INDEX - An index or table of fasteners that may be disassembled during transporter maintenance and that were initially assembled with anaerobic locking compound shall be provided to facilitate correct maintenance. This document shall also identify the type of locking compound used.

6.3.3.3 MISCELLANEOUS FASTENERS – All fasteners for covers, panels, brackets or other non-critical components shall be selected by the Contractor to meet the needs of the application.

6.3.3.4 GRADE INDENTIFICATION – All structural and mechanical bolts, screws and nuts shall have identification markings required by the relevant ASTM or SAE specifications.

6.3.3.5 INTERNALLY THREADED CONNECTIONS – All internally threaded fastener connections for operational critical components shall be sized to ensure adequate thread engagement is provided for the externally threaded fasteners develop their full tensile strength. All nuts shall have a minimum of one thread pitch of the bolt protruding above the nut top surface after the fastener is installed.

6.3.4 SURFACES – Surfaces of castings, forgings, molded parts, stampings and welded parts shall be cleaned and free from sand, dirt, fins, sprues, flux or other harmful or extraneous materials. External surfaces shall be smooth. Edges shall be rounded or beveled unless sharpness is required to perform a function.

6.3.4.1 PAINTING – The equipment shall be properly painted. Paint specification shall be approved by the Government prior to application. Prior to painting, surfaces shall be properly prepared and primed. Painting shall provide a highly wear-resistant finish that guarantees continued protection to the surfaces covered against the specified environment in Section 5.5, under all service conditions. The colors red, yellow, and magenta shall not be used without written Government approval. No objection will be raised by the Government against OEM logos and similar small graphics/signage that are in color other than those specified herein.

6.3.4.1.1 COLOR SCHEME – The vehicles shall be painted/marked as follows:

Overall vehicle body: Safety Orange, PPG95-805.

Access Hatch Striping/No-Load Area Demarcation: Black stripes

Lettering/graphics/signage, printed, painted, or otherwise: Black

The contactor shall submit a proposed paint scheme for review and approval by

NNSY.

6.3.4.2 ALUMINUM SURFACES – Aluminum parts for use outdoors shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint.

6.3.4.3 FERROUS PARTS – Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable.

6.3.4.4 DISSIMILAR METALS – Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion and without compromising joint tightness or fatigue life.

6.4 STRUCURAL COMPONENTS

6.4.1 STRUCTURAL MEMBERS – The main frame members shall be adequately braced with sufficient members and cross-members to form a rigid structure with sufficient strength for the loads imposed. When the LHS is loaded with maximum rated loads, the maximum stress in each frame member(s) shall be not greater than 50 percent of the frame material minimum yield strength.

6.4.2 WELDING STANDARDS FOR STRUCTURAL MEMBERS – All welding, fabrication and inspection shall be in accordance with the requirements of American Welding Society (AWS) D14.4. If an equivalent alternate specification is recommended by the Contractor, it shall be identified in writing and submitted to the Government for approval.

6.4.3 SPECIFIC STRUCTURAL REQUIREMENTS FOR SELF-PROPELLED BASE

6.4.3.1 AREA OF DECK – The maximum dimensions of the deck of the self-propelled base shall not exceed the maximum envelope shown in Figure 3.

6.4.3.2 CONNECTION TO LOAD / FIXTURING – The decks of each self-propelled base shall have the capability to be mechanically attached to the load and/or associated LHS fixture. The deck will incorporate a symmetrical array of attachment points comprised of replaceable threaded flanged nuts for use with appropriately sized fasteners/hardware as provided by the buyer. The maximum stresses in the attachment hardware shall be no greater than 50 percent of the material minimum yield strength. Welding of the load and / or fixture to the deck of the self-propelled base is not permitted.

Removable/reusable non-metallic plugs shall be provided to protect tapped holes.

6.4.3.3 IDENTIFICATION OF LOAD SUPPORT AREAS – All load supporting areas on the deck of the self-propelled base shall be clearly and permanently identified. All non-load supporting areas of the deck shall be marked as such.

6.4.3.4 PROTECTION OF OPENINGS ON TOPSIDE OF SELF-PROPELLED BASE –

Openings larger than 6 inches in their greatest dimension on the topside of self-propelled base shall be filled with lightweight nonskid decking such that one person can remove or open the section (for maintenance access). This decking shall be flush with the surrounding deck and as such shall be able to withstand a local load of 100 pounds per square foot without damage. The decking shall be restrained to prevent lifting by the wind.

6.4.4 SPECIFIC STRUCTURAL REQUIREMENTS FOR LHS MODULAR FIXTURE

6.4.4.1 CONNECTION TO SELF PROPELLED BASE – The frame of each LHS modular fixture shall have the capability to be mechanically attached to the self-propelled base. The frame will incorporate the necessary fastener holes for use with appropriately sized fasteners/hardware. The maximum stresses in the attachment hardware shall be no greater than 50 percent of the material minimum yield strength.

Welding of the fixture to the deck of the self-propelled base is not permitted.

6.5 LIFTING/HANDLING

6.5.1 LIFTING BY CRANE – The self-propelled bases and modular fixtures will be lifted independently into and out of a dry dock by means of a crane. Each self-propelled base and modular fixture shall incorporate independent lifting points with appropriately sized permanent pad eyes or tapped holes for swivel hoist rings.

6.5.2 LIFTING POINTS – The equipment shall be provided with pad eyes or tapped holes for swivel hoist rings, oriented about the vertical center of gravity, to allow for safe handling and transport by overhead crane. When suspended in accordance with the lifting diagram specified in Section 6.5.2.7, the equipment shall hang level within five degrees of true vertical.

6.5.2.1 LOCATION OF LIFTING POINTS – The lifting/handling lift points shall be located on or near the four corners of the self-propelled bases.

6.5.2.2 PROTECTION OF LIFTING POINTS – Removable/reusable non-metallic plugs shall be provided to protect any threaded lifting holes.

6.5.2.3 FACTOR OF SAFETY OF LIFTING POINTS – The lifting/handling lift points shall be sized such that each point is capable of supporting 50% of the weight of the self-propelled base or modular fixture along with components while ensuring the combined material stresses have a factor of safety of ≥ 3.0 on material minimum yield strength and factor of safety ≥ 5.0 on material minimum ultimate strength. All lift points should be oriented such that the rigging will converge to one lift point (i.e., the crane’s hook). Each lift point shall be subject to a proof test of 200% of the maximum design load for that lift point.

6.5.2.4 DEPTH OF TAPPED HOLES – If tapped holes are provided for use with swivel hoist rings, the threaded portion of those holes must have a depth of at least 1 ½ times the root diameter of the threads but not less than the minimum thread engagement in accordance with the swivel hoist ring manufacturer’s recommendations.

6.5.2.5 LIFTING POINT IDENTIFICATION – All lifting points shall be clearly identified with a permanent label plate attached to the structure. The label plate shall specify the maximum rated capacity.

6.5.2.6 IDENTIFICATION OF LHS COMPONENT WEIGHT – The weight of each self-propelled base, LHS modular fixture, and height spacer (Kit 3) as shown in NAVSEA Drawing No. 8357284 shall be permanently labeled on at least two sides of each respective self-propelled base. This labeled weight shall be accurate to +2%, -0% of the actual weight of LHS component and shall be rounded up to the nearest 100 lbs.

6.5.2.7 LIFTING DIAGRAM – A lifting diagram illustrating the approved lifting locations and capacities shall be provided for Government approval. The Contractor shall supply any and all special rigging hardware.

6.6 SELF-PROPELLED BASE DETAILED REQUIREMENTS

6.6.1 PROPULSION – The LHS shall be self-propelled.

6.6.1.1 PROPANE INTERNAL COMBUSTION ENGINE – The primary source for motive force shall be provided by propane internal combustion engine driving a generator or alternator, feeding electric motors.

6.6.1.2 COOLING SYSTEM – The cooling system shall be of sufficient capacity to permit full load operation with air at a temperature of 120 degrees F entering the radiator. The transporter shall be delivered with glycol base antifreeze, providing protection to -20 degrees F.

6.6.1.3 AIR FILTERING – The engine air intake shall be provided with filtering system.

The intake shall be located to minimize ingestion of ground level dust and debris.

6.6.1.4 NOISE CONTROL – Noise quieting of the engine and exhaust system shall include a commercially available muffler system to reduce noise to a maximum 84 dB at 3ft. Use of sound deadening material which will absorb oil and become a fire hazard is prohibited. In the event that audible noise levels cannot be maintained below the limits specified, the machine(s) shall be placarded with requirements to wear hearing protection during operation. Signage shall be approved in writing by the Government prior to installation.

6.6.1.5 PROPANE TANKS – Commercial off-the-shelf propane tanks shall be used.

They shall be provided with a fuel level indicator. The contractor shall also provide 4 spare tanks.

6.6.1.6 POWERPLANT START-UP – The LHS shall be capable of startup and operation under any and all combinations of environmental conditions specified in Section 5.5, with a maximum warm-up time of 20 minutes. Tank and engine heaters may be used to satisfy this requirement.

6.6.2 SECONDARY SOURCE OF MOTIVE POWER – The LHS units shall be provided with a socket type feed for an umbilical electric cord as secondary power supply (440/480 VAC, 60 cycles, three phase). Receptacles shall be located on the side or end of each unit, such as not to interfere with loaded and unloaded operations specified herein.

6.6.2.1 UMBILICAL CORD – Each self-propelled base shall be provided with a 100 ft.

long electrical umbilical cord, sheathed in abrasion resistant material to prevent damage as the LHS moves across unpolished concrete and asphalt surfaces. Means shall also be provided to easily store and deploy the umbilical cord for each self-propelled base (either internal or external). Rubber is not an acceptable sheathing material.

6.6.3 EMERGENCY STOPS – Emergency stop controls shall be provided at the operator’s panel, wireless remote, and on each side of the transporter. A minimum of one emergency stop shall be located on each side of the transporter. These controls shall be capable of being linked together both via wireless communication and wired connection (in the event wireless cannot be used) such that activation of any one emergency stop control will stop all transporters operating simultaneously and will engage the parking brake feature.

6.6.4 EMERGENCY PARKING BRAKE RELEASE - Means shall be provided for releasing the braking feature in the event of vehicle breakdown.

6.7 LIFT SYSTEM – SELF-PROPELLED BASE:

6.7.1 LOAD CAPACITY – The rated load capacity shall be a minimum of 50 tons for each self-propelled base applied at the surface of the deck at geometric center. In addition, the self-propelled bases shall be designed to ensure overall stability and capacity to account for the weights and centers of gravity of components identified in Section 6.7.1.1 and as provided by the buyer.

6.7.1.1 VARIABLE GEOMETRY COMPONENTS -The LHS modular fixture, as designed in NAVSEA Drawing No. 8357284, shall have the ability to independently handle the four major components of the LWWAA. Figure 4 provides the general configurations and the weights of the components that will be handled by the LHS modular fixture are included below. These components include:

• Component 1: Cable Modular Array Assembly (CMAA) weight 10,000 Ibs

• Component 2: Short Fairing Assembly (SFA) weight 1850 Ibs

• Component 3: Long Fairing Assembly (LFA) weight 2850 Ibs

• Component 4: Aft Array Fairing Assembly (AAFA) weight 2285 Ibs

The geometries of these components are complicated and the composite materials from which they are constructed may be sensitive to the way they are handled. The fixture must handle these items in a manner that prevents damage to the components, the submarine, and the handling gear. Features for transporting the Toepiece Assemblies (TA)'s and Transition Covers (TC)'s shall be integrated into the LHS. The weight of a single TA is 750 Ibs. The weight of a single corner TC is 65 Ibs. The weight of a single center TC is 150 Ibs.

Figure 4 – Major Components of the LWWAA Handled by the LHS

(Toepieces and Transition Pieces not Shown for clarity)

6.7.1.2 COMPONENT ENGAGEMENT FRAME – The modular fixture will incorporate a reconfigurable Component Engagement Frame (CEF), which will physically engage and support LWWAA components during installation and removal. It may incorporate removable pieces (if necessary to allow for engagement of all LWWAA components) only if the design allows for their installation and removal by hand by two personnel (or less), without the aid of overhead rigging gear. The entire CEF assembly will be liftable by use of overhead crane.

6.7.1.3 FUNCTION AS A LIFTING FIXTURE – The CEF will also function as a lifting fixture for lifting and turning components of the LWWAA into and out of the dry dock.

6.7.1.4 CEF LIFT POINTS – The CEF will incorporate independent lift points, allowing it to be lifted free of LHS modular fixture. Each lift point shall be capable of supporting 50% of the total load. The lift points shall meet the requirements of Section 6.5.

Figure 5 – Arrangement of LWWAA on Hull in Relation to LHS (Toepieces and Transition Pieces removed)

6.7.1.5 HEIGHT ADJUSTMENT – In addition to the precision vertical movements provided by the self-propelled bases, the height of the vertical columns of the fixture shall be adjustable such that both sides of the fixture raise or lower in unison, using manual input from a single device (e.g., hand wheel) or with a hydraulic assist operated by a single worker. The fixture shall allow for 12 in. of vertical adjustment.

6.7.1.6 INDEPENDENT JACK SCREWS – In addition to the horizontal and vertical precision movements provided by the self-propelled bases, independently operated jack screws will provide motion of the CEF. The design of the interface between the jack screws and the CEF shall prevent binding due to the screws being adjusted to differing lengths while supporting the CEF and the load. Each jack screw shall be operable by a single worker, when working with loads up to and including the maximum capacity for the fixture. Each jack screw shall allow for 12 in. of stroke.

6.7.1.7 STABILITY OF FIXTURE – The fixture shall be stable and shall not tip when unloaded and free standing on the ground pier side.

6.7.1.8 PERSONNEL PLATFORM – The modular fixture will incorporate a work platform from which personnel can safely access fasteners securing the LWWAA to the hull of the submarine and the components of the fixture itself (where necessary). The platform shall meet all requirements of 29 CFR Part 1910 Occupational Safety and Health Standards, Subpart D – Walking–Working Surfaces, 1910.23(c).

6.7.1.9 BUILD HEIGHT SPACER – To account for potential differences in the keel heights (Baseline), a 30” and 36” spacer (Refer to Figure 2) may be required to raise the modular fixture (when mounted to the self-propelled bases). Each spacer shall have integral lift points (meeting the requirements of Section 6.5) and shall have its weight marked on it in accordance with Section 6.5.2.6.

6.7.2 METHOD OF LIFT – Motive force for raising and lowering the deck shall be by means of hydraulic cylinder(s).

6.7.3 HYDRAULIC LIFT SYSTEMS – The lift system shall be provided with a feature to prevent an uncontrolled lowering or loss of deck height in the event of a hydraulic system hose or piping failure (i.e., cylinder mounted check valves).

6.7.4 TRAVEL AT SUSPENSION LIMITS – The LHS shall be capable of traveling throughout the full stroke of its suspension under any and all combinations of environmental and grade conditions specified in Section 5.5 with the following restrictions:

a) Under load, travel within the last 2” of stroke at the upper limit [31 in. to 33 in.] and the lower limit [27 in. to 29 in.] in 25% speed mode and jog modes only.

b) Unloaded, travel throughout suspension stroke in all speed modes.

6.7.5 RATE OF LIFT – The lift system raise and lower positioning speed shall be 9 inches per minute maximum in the loaded condition. For concurrent operations, all self-propelled bases must have the same lifting positioning speed within ±2%.

6.7.6 NORMAL MODE OF LIFTING – The normal mode of lifting and lowering shall be by concurrent operation of all four corners (i.e., automatic leveling of the load decks).

6.7.7 PITCH AND ROLL – The LHS controls shall provide a mode that facilitates pitch and roll maneuvers, when directed by the operator, whether operating in single or concurrent modes. The contractor shall identify range of operation.

6.7.8 LOAD INDICATION – Load indication shall be built into the transporters, allowing for the resolution of loads at the reaction points. Loads shall be displayed at the control station and on the hand held controller(s). The display readout shall be in pounds. The accuracy of the displayed load shall be such that the indicated load is +/- 3% of actual load over the range of 15 to100% of rated load full scale

6.8 MAINTAINING LOAD POSITION – SELF-PROPELLED BASE

6.8.1 HOLDING BRAKES – Each self-propelled base shall include holding/parking brakes that automatically engage whenever there is no drive or rotate inputs from the operator. The brakes shall automatically disengage whenever the operator provides input to either drive or rotate the self-propelled base(s). The braking system shall be designed such that improper action by the operator cannot result in loss of function of the holding brakes. The holding brakes shall be capable of maintaining the self-propelled base(s) in position, while carrying the maximum rated load, in all steering modes, under conditions specified in Section 5.5. The holding brakes shall automatically engage in the event of a loss of power. The vehicle shall be provided with the ability to electronically test for and indicate satisfactory brake holding torque for each individual drive motor.

6.8.2 ELECTRONIC BRAKING – Each self-propelled base shall rely on its electronic drive to slow and stop its motion. The electronic drive will apply the appropriate input to the electric motors to maintain position until the holding brakes engage. Brake resistors shall not be used without written approval of the Government.

6.8.3 MECHANICAL LOAD SUPPORT – Built in mechanical means shall be provided to transfer the load from the hydraulics to the ground to prevent loss of vertical position due to hydraulic sag. This may be accomplished by use of jack screws, etc. The mechanical means shall have the ability to be actuated from the control station and/or the handheld controller and must have the ability to be manually deployed. The resulting floor loading must not exceed 1000 psi. In addition, even if positive mechanical stops have not yet been set, the vertical positioning method shall prevent uncontrolled lowering of the load if hydraulic pressure is lost (i.e., cylinder mounted check valves).

6.8.4 EMERGENCY LOWERING – Means shall be provided for manually lowering the transporter in the event of a breakdown.

6.9 HYDRAULIC SYSTEM

6.9.1 HYDRAULIC SYSTEM CAPACITY – The hydraulic system shall have sufficient capacity to continuously drive, maneuver and elevate the bed at maximum rated load.

Lift and lower speeds shall be per Section 6.7.

6.9.2 HYDRAULIC SYSTEM COOLING - Sufficient cooling shall be provided to limit the temperature of the hydraulic system to a value suitable to the application per the design requirements of the hydraulic system.

6.9.3 HYDRAULIC SYSTEM PRESSURE – Proof pressure of hydraulic system piping and components shall be a minimum of 1.25 times normal operating pressure (not to exceed 2400 psig) and shall be greater than the maximum pressure that may occur due to abnormal operating conditions such as transient system impact loading, or pressure intensification due to differential areas of system components. External leakage at proof pressure shall be zero. Means shall be provided to perform a 1.25 X operating pressure hydrostatic test that does not require modification of the hydraulic system configuration prior to test performance (removal of pressure relief valves, manually changing system pressure, etc.) Manual manipulation of permanently installed valves is acceptable.

6.9.4 HYDRAULIC FLUID - The operating medium of the hydraulic system is to be a common grade of domestically produced commercial hydraulic fluid, and shall be specified by the Contractor. For minimization of inventory, the fluid used shall be compatible with Shell Tellus MX32, which is the fluid used in the transporter vehicles currently operated by the Shipyards.

6.9.5 HYDRAULIC SYSTEM COMPONENTS – The Contractor shall provide the U.S.

manufacturer’s identification number for all hydraulic system pipe fittings, seals, and hoses.

6.9.5.1 PRESSURE GAUGES – Pressure gauges and a low pressure alarm shall be provided for the hydraulic system. Gauges may be mounted in the engine area, and are not necessarily required in the control station.

6.9.5.2 SOFT GOODS INDEX - A list of all serviceable/replaceable hydraulic system soft goods (seals, O-Rings, back-up rings, gaskets, etc) shall be provided. This list shall identify all components by manufacturer, manufacturer part number, and, wherever appropriate, by standard identification number (MIL-S, AS568, etc.).