Attachment 0006 ATPD 2290 Family of Loaders.pdf

7 June 2011

Purchase Description For

FAMILY OF LOADERS

LIGHT LOADERS, TYPE I AND TYPE II

AND

HEAVY LOADERS, TYPE I AND TYPE II

1. SCOPE

1.1 Scope. This purchase description covers a family of militarized commercial, self-propelled, pneumatic tired front-end loaders. The family of loaders consists of four types; two sizes of Light loaders and two types of Heavy loaders.

1.2 Classification. The FOL are defined as a scoop type, pneumatic tire, four wheel drive, articulated frame steer, diesel engine driven loaders. The FOL shall be of the following types:

Light, Type I, ABN/AASLT, 1.6 Cubic Yard Multipurpose Clamshell Bucket

Light, Type II, General Purpose, 2.5 Cubic Yard Multipurpose Clamshell Bucket

Heavy, Type I, 4.5 Cubic Yard Rock Bucket

Heavy, Type II, 5.0 Cubic Yard General Purpose Bucket

1.2.1 Light Loaders. The Light Loader(s) shall be classified as a Type I or Type II Light loader that is air transportable by C-130 and C-141. Light Type I is also air-drop-able, and air assault helicopter transportable.

1.2.2 Heavy Loaders. The Heavy Loader(s) shall be classified as a Type I or Type II Heavy loader that is air transportable by C-5 and C-17.

1.3 Required / Desired. Within this procuring document, the requirement refers to the minimum that will be expected or accepted. Desired refers to the Army’s objective that it would like to achieve.

2. APPLICABLE DOCUMENTS

2.1 Government Documents.

2.1.1 Specifications and Standards. The following military specifications, standards, and handbooks are part of this document to the extent specified herein. Unless otherwise specified in the procurement acquisition document, the latest revision of these specifications and standards at time of solicitation shall be adhered to. Documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS).

(Unless otherwise indicated, copies of federal/military specifications, standards, and handbooks are available from the Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.)

Standards:

Federal

FED-STD-595 Colors Used in Government Procurement A-A-50271 Plate, Identification

Military

NATOSTANAG-4019 Emergency Towing Facilities NATOSTANAG-4074 Auxiliary Power Unit Connections for Starting Tactical

Land Vehicles MIL-DTL-53072 CARC System Application Procedures and Quality

Control Inspection.

MIL-HDBK-669 Loading Environment and Related Requirements for

Platform Rigged Airdrop Material MIL-HDBK-1791 Designing for Internal Aerial Delivery in Fixed Wing

Aircraft MIL-PRF-2104 Lubricating Oil, Internal Combustion Engine, Combat and

Tactical Service/Tactical Services MIL-PRF-2105 Lubricating Oil, Gear, Multipurpose MIL-PRF-10924 Grease, Automotive and Artillery MIL-PRF-23827 Grease, Aircraft and Instrument, Gear and Actuator

Screw, NATO Code Number G-354 MIL-PRF-46167 Lubricating Oil, Internal Combustion Engine, Arctic MIL-PRF-46170 Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic

Hydrocarbon Base MIL-PRF-46176 Brake Fluid, Silicone, Automotive, All Weather, Operational and Preservative, Metric MIL-STD-130L Standard Practice Identification Marking of U.S. Military

Property MIL-STD-209 Interface Standard for Lifting and Tie down Provisions for

Military Equipment MIL-STD-461 Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment

MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems

MIL-STD-810 Environmental Test Methods

MIL-STD-814 Requirements for Tie down, Suspension and Extraction Provisions on Military Material for Air Drop

MIL-STD-913 Requirements for the Certification of Externally Transported Military Equipment by Department of Defense Rotary Wing Aircraft

MIL-STD-1179 Lamps, Reflectors, Associated Signaling Equipment for Military Vehicles

MIL-STD-1366 Interface Standard for Transportability Criteria MIL-STD-2169 High Altitude Electromagnetic Pulse (HEMP)

Environment MIL-V-81940/1 Valve, Sampling and Bleed, Hydraulic, Type II Systems MS 51113 Switch, Vehicular Lights, 24 Volt DC (Waterproof)

2.1.2 Other Government documents drawings, and publications.

US ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND (TACOM)

DRAWINGS

ME 13229E8014 and 13229E8016 - Bracket Assembly Rifle Stowage

REPORT NO. CR-82-588-003 Rev 1, Feb 1988 – Design Guide For Vehicle Diagnostic Connector Assemblies

DEPARTMENT OF LABOR (DOL)

29 CFR 1910- Occupational Safety and Health Standards (OSHA) 29 CFR 1926- Safety and Health Regulation for Construction

(The Code of Federal Regulations (CFR) and the Federal Register (FR) are for sale on a subscription basis by the Superintendent of Documents, U.S. Government printing office, Washington, DC 20402. When indicated, reprints of certain regulations may be obtained from the Federal agency responsible for issuance thereof).

MILITARY TRAFFIC MANAGEMENT COMMAND TRANSPORTATION

ENGINEERING AGENCY (MTMCTEA)

MTMCTEA PAMPHLET 70-1 – Transportability for Better Deployability

(Application for copies should be addressed to the Military Traffic Management Command Transportation Engineering Agency, ATTN: MTTE-TR, 720 Thimble Shoals Blvd, Suite 130; Newport News, VA 23606-4537)

2.2 Other Publications. The following document(s) form a part of this specification to the extent specified herein.

AMERICAN WELDING SOCIETY, INC. (AWS)

AWS D14.3 – Earthmoving and Construction Equipment Welding, Section 5

(Application for copies should be addressed to the American Welding Society, Inc., 550 NW LeJune Road, Miami, FL 33126)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

Z535.1 - Safety Color Code Z535.3 - Criteria for Safety Symbols Z535.4 - Product Safety Signs and Labels B56.6 - Safety Standard for Rough Terrain Forklift Trucks

(Applications for copies should be addressed to the American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018)

AMERICAN TRUCKING ASSOCIATION (ATA)

Road Limitations

(Application for copies can be addressed to ATA Inc, 2200 Mill Road, Alexandria, VA 22314-4677).

ASSOCIATION OF AMERICAN RAILROADS (AAR)

General Rules Governing the Loading of Commodities on Open-Top Cars and Trailers

(Application for copies should be addressed to the IRF, 525 School St., Washington, D.C. 20024)

INTERNATIONAL ROAD FEDERATION (IRF)

Size and Limit

(Application for copies can be addressed to IRF, 525 School Street, Washington, DC 20024).

SOCIETY OF AUTOMOTIVE ENGINEERS, INC (SAE)

AMS-M-7866 Molybdenum Disulfide, Technical, Lubrication Grade J38 Lift Arm Support Device for Loaders J88 Sound Measurement - Earth moving Machinery – Exterior J98 Personnel Protection for General Purpose Industrial Machines J115 Safety Signs J185 Access Systems for Off-Road Machines J231 Minimum Performance Criteria for Falling Object Protective Structure

(FOPS)

J276 Steering Frame Lock for Articulated Loaders and Tractors J386 Operator Restraint System for Off-Road Work Machines J514 Hydraulic Tube Fittings J551 Performance Levels and Methods of Measurements of Electromagnetic

Radiation from Vehicles and Devices J674 Safety Glazing Materials - Motor Vehicles J732 Specification Definitions-Loaders J742 Capacity Rating Loader Buckets J753 Lubrication Chart - Construction and Industrial Machinery J818 Rated Operating Load for Loaders J821 Electrical Wiring Systems for Construction and Agricultural and Off-Road

Machines J833 USA Human Physical Dimensions J898 Control Locations for Off- Road Work Machines J899 Operator’s Seat Dimensions for Off-Road self-propelled Machine J919 Sound Measurement-Off Road Machines-Operator Singular Type J925 Minimum Service Access Dimensions for Off-Road Machines J994 Alarm- Backup- Electric Laboratory Performance Testing J1013 Measurement of Whole Body Vibration of the Seated Operator of Off-

Highway Work Machines J1040 Performance Criteria for Roll- over Protective Structure (ROPS) for

Construction, Earthmoving, Forestry, and Mining Machines J1113 Electromagnetic Susceptibility Measurement Procedures for Vehicle

Components J1166 Sound Measurement - Off-Road Self- Propelled Work Machines -

Operator - Work Cycle J1176 External Leakage Classifications for Hydraulic Systems J1197 Rated Operating Load for Loaders Equipped with Material Forks J1308 Fan Guard for Off- Road Machines J/ISO 3450 Braking Systems of Rubber-Tired Machines J1503 Performance Test for Air- Conditioned, Heated and ventilated Off-Road

Self- Propelled Work Machines J1511 Steering for Off-Road, Rubber-Tired Machines J1587 Joint SAE/TMC Electronic Data Interchange Between Microcomputer

Systems in Heavy Duty Vehicle Applications J1703 Motor Vehicle Brake Fluid

J1708 Serial Data Communication between Microcomputer Systems in Heavy Duty Vehicle Applications

J1908 Electrical Grounding Practice, Standard J1939 Recommended Practice for Truck and Bus Control and Communications

Network.

J1939/13 Off-Board Diagnostic Connector

(Application for copies should be addressed to the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096.)

2.3 Order of Precedence. In the event of a conflict between the text of this purchase description and the references cited [except for associated detail specifications or Military Standards (MS)], the text of this purchase description shall take precedence.

Nothing in this purchase description, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Description and Characteristics. All features and components listed as standard equipment in the contractor’s published specification brochures and catalogs, or normally furnished to commercial customers as standard equipment, shall be furnished.

All optional components or features required to meet this document shall be furnished.

All loader(s) shall be provided with all necessary operating accessories customarily furnished with loaders of this type together with such attachments necessary to enable the loader to function in accordance with requirements stated herein. Manufacturer decals, logos and model numbers shall not be displayed on the loader. The FOL shall conform to all Federal Law and regulations governing safety, noise levels and pollution, which are in effect on the date of proposal or publicly known to be scheduled for implementation during the performance of the contract.

3.1.1 Light Loaders. The Light Loaders shall be capable of excavating, digging, lifting/loading, stripping, leveling, stockpiling, and clamshell for obstacle removal operations. Interchangeability of attachments shall be accomplished IAW 3.1.3.1.

3.1.1.1 Bucket for Light Type I and Type II.

a. The Light Type I loaders shall have a multipurpose/ 4 in 1 clamshell bucket with a SAE J742 heaped Capacity rating of not less than 1.6 cu yd, desired 2.1 cu yd.

Material density rating: minimum 3000 lbs. / yd3

b. The Light Type II loaders shall have a multipurpose/ 4 in 1 clamshell bucket with a SAE J742 heaped Capacity rating of not less than 2.5 cu yd.

Material density rating: minimum 3000 lbs. / yd3

Bucket type: A minimum of 8 bolt on replaceable teeth (tips and adapters), and a welded on cutting edge. A multipurpose bucket clam indicator shall be attached to the 4 in 1 clamshell bucket that indicates the position of the clam whether it is fully open or fully closed or somewhere in between.

3.1.1.2 Forklift attachments for Light Type I and II. When specified the following attachment shall be furnished (See 6.2):

a. The Light Type I loaders shall have a forklift with a minimum capacity of 4,000 lbs., desired 6000 lbs., with a 24" Load Center and 40" floating forks, when rated IAW SAE J1197. The forklift shall maintain a level lift with a constant (approximate) angle to the ground throughout the lifting range without control adjustment by the operator.

b. The Light Type II loaders shall have a forklift with a minimum capacity of 6,000 lbs., desired 8000 lbs., with a 24" Load Center and 40" floating forks, when rated IAW SAE J1197. The forklift shall maintain a level lift with a constant (approximate) angle to the ground throughout the lifting range without control adjustment by the operator.

3.1.2 Heavy Loaders. The Type I and Type II Heavy loaders shall be identical base machines with different buckets as defined herein. The Heavy Loaders shall be capable of excavating, digging, lifting/loading, stripping, leveling, and stockpiling operations.

Interchangeability of attachments shall be accomplished IAW 3.1.3.2.

3.1.2.1 Bucket for Heavy Type I and Type II.

a. The Heavy Type I loaders shall have a rock bucket capable of operating in quarries to stock pile and lift blast rock (for shot and crushed rock) with a SAE J742 heaped capacity: minimum 4.5 cubic yards.

Material density rating: minimum 3,000 lbs. /yd3 Bucket type: spade nose, “v” edge, or wedge, teeth, bolt on segments, and corner guards

b. The Heavy Type II loaders shall have a general-purpose bucket (for excavating, digging, loading, stripping, leveling, and stockpiling) with a SAE J742 heaped capacity: minimum 5.0 cubic yards.

Material density rating: minimum 3,000 lbs./yd3 Bucket type: penetration teeth, bolt on segments, and corner guards

3.1.2.2 Forklift Attachment for Heavy Type I and II. When specified the following

a. A forklift with a minimum capacity of 10,000 lbs., desired 13,000 lbs. with a 48" Load Center and 72" forks, when rated IAW SAE J1197.The fork tines shall be capable of fork positioning nominally between 9 inches maximum, inside to inside in closed position to a minimum outside to outside of 75 inches in maximum spread position, accomplished from the cab by the operator

3.1.2.3 Sweeper Attachment for Heavy Type I and II. When specified the following

a. A hydraulically powered rotary sweeper with a brush face width a minimum of two inches wider than the overall width of the vehicle (without the bucket).

3.1.3 Attachment Interchangeability.

3.1.3.1 Light Loader Attachment Interchangeability. The Light loaders shall have the capability to quickly connect/disconnect the bucket and attachments by one soldier without tools in five minutes. It is desired this operation be performed from inside the cab. When disconnecting the attachments, the loaders should not leak any hydraulic fluid as measured by SAE J1176 Class 3: Formation of nonfalling droplet. The Light Type I/II will have the capability to accept additional front-end attachments. It is desired that all attachments that do not exceed the capability of the host loader will be interchangeable between the Light Type I/II loaders.

3.1.3.2 Heavy Loader Attachment Interchangeability. The Heavy Loaders shall have the capability to quickly connect/disconnect the bucket and attachments using a quick coupler. When disconnecting the attachments, the loaders should not leak any hydraulic fluid as measured by SAE J1176 Class 3: Formation of nonfalling droplet. The Heavy Loaders will have the capability to accept additional front-end attachments. The Government desires to connect/disconnect attachments without tools.

3.1.4 Pre-Planned Product Improvement. To provide maximum operational flexibility and utility for commanders, in support of future missions, it is highly desired that the Heavy Type I and Type II FOL vehicles be capable of adding/removing with tools organic to the unit and operating/utilizing the following attachment/devices:

a. An attachment with compaction capability (e.g. a roller) with little or no modification required.

b. A scraper attachment, either pushed or towed, with a five cubic yard capacity, or an eight cubic yard capacity.

c. A backhoe attachment with a 3/4 cubic yard bucket, with little or no modification required.

3.2 Performance. The FOL and attachments shall withstand the usage encountered in military operations such as transport by helicopter, air delivery, loading trucks from stockpiles, stockpiling material, and excavating undisturbed and compacted soil without breakage, malfunctions or permanent deformation.

3.2.1 Stability. The FOL vehicles with full bucket, in carry position and on unpaved surface shall negotiate 27% side slopes and 50% longitudinal slopes without any wheel of the loaders losing contact with the ground. The FOL vehicles with forklift attachment shall negotiate 15% circular slopes and 30% longitudinal slopes without any wheels of the loaders losing contact with the ground. An inclinometer shall be attached to the loader in clear view of the operator for use as a side slope rollover warning device.

3.2.2 Operating loads. The FOL vehicles shall have operating loads in compliance with

SAE J818.

3.2.3 Tipping loads. The FOL vehicles shall have a full turn, static tipping load per SAE J732 of not less than the amount shown below using the bucket prescribed for each loader.

a. Light Type I 9,600 lbs., 12,600 lbs. desired

b. Light Type II 15,000 lbs.

c. Heavy Type I 27,000 lbs.

d. Heavy Type II 30,000 lbs.

3.2.4 Dump Height and Reach. The Light Loaders shall be capable of lifting, clearing and dumping loads into the Army’s M929 (83" sideboard height) and FMTV 5-ton dump trucks (80” side board height). It is desired that the Light loaders be capable of lifting, clearing and dumping into the Army’s M917 dump truck (114” side board height) and the Palletized Load System-Engineer Mission Module Dump Body (PLS-EMM-DB) (Truck mounted 124” side board height and trailer mounted 116” side board height). The Heavy loaders shall be capable of lifting, clearing and dumping loads into the Army’s M917 truck dump truck and the PLS-EMM-DB. All measurements should be taken using the buckets prescribed for each loader within this PD including teeth etc., with the bucket at full lift and at a dump angle of 45 degrees in accordance with SAE J732. It is desired that All FOL vehicles be capable of lifting, clearing and dumping loads into the center of the dump beds.

3.2.5 Travel Speed. The FOL vehicles shall be capable of traveling at a minimum top speed of 20 MPH on the first three road classifications (See 6.5). 25 MPH is desired. All FOL loader(s) shall also be capable of working on rough, soft, unimproved ground and the last two roads conditions (See 6.5). The Heavy Type I Loader(s) shall be capable of working in and around rock quarries while traveling over blast rock, mud and snow.

3.2.6 Operating Temperature The FOL shall be capable of operating in hot and basic climate regions (+120°F to -25°F). An arctic cold weather starting aid kit, (See 3.9.6), can be used for starting and operating in cold regions from -25°F to -40°F. The FOL shall be capable of starting within 45 minutes and operating under full-load conditions within fifteen minutes after engine start for vehicles destined to arctic areas.

3.2.7 Fording. The FOL vehicles shall start and operate during and after fording operations in fresh water to any depth up to 20 inches including wave action without damage and without leakage of water into reservoirs containing lubricants or fluids.

3.2.8 Lift Capacity. The FOL vehicles shall have a lift capacity conforming to the requirements of SAE J818 and J732 at the carry / maximum height positions.

3.2.9 Breakout Force. The FOL vehicles shall have a breakout force per SAE J732 and J742 of not less than the amount shown below.

a. Light Type I 13,500 lbs.

b. Light Type II 19,500 lbs.

c. Heavy Type I with Quick Coupler (QC) & Rock Bucket 26,000 lbs

d. Heavy Type II with General Purpose Bucket (w/o QC) 42,000 lbs.

3.2.10 Clam Closure Force. The closure force at the lip of the closed clam for the Light Type I/II shall be not less than 5000 lbf. / 7000 lbf. respectively.

3.3 Transport Requirements. The loader(s) shall have the capability of being transportable worldwide by rail, marine, highway, and air modes. Guidance on transportability criteria is defined in MIL-STD-1366. If disassembly is required to meet any of the transportation requirements, it shall be accomplished in one hour or less, by two soldiers, with on board tools and BII and with available lift assets. No disassembly is desired. Disassembly by use of cutting/welding equipment is NOT allowed.

3.3.1 Rail Transport. The FOL shall be rail transportable in CONUS and NATO countries without restrictions. Reference MIL-STD-1366. The FOL shall be capable of withstanding shock loads resulting from rail impact testing without failure, damage, or permanent deformation. When loaded on a 51-inch high rail car, the FOL shall meet the dimensional requirements of the Association of American Railroads (AAR) Outline Diagram for Single Loads, Without End Overhang, on Open-Top Cars. When mounted on a 51.4-inch high railcar, the FOL shall meet the dimensional requirements of Gabarit International de Chargement (GIC) equipment gauge diagram. These diagrams apply to standard gauge rail lines in the Continental United States (CONUS) and NATO countries. All FOL vehicles shall be transportable by rail with disassembly in one hour or less using equipment organic to the unit. Transport by rail without disassembly is desired.

3.3.2 Marine transport. The FOL vehicles shall be capable of transport on roll-on/roll-off (RORO), break bulk (general cargo), and barge carrying (LASH and SEABEE) ships, as well as Army watercraft. All FOL vehicles shall be transportable by marine vessels with disassembly in one hour or less using equipment organic to the unit. Transport by marine vessels without disassembly is desired.

3.3.3 Highway transport. The Light loaders shall be highway transportable and self-loading onto the M172 series/semi-trailer, which has a deck height of 39.5”, while meeting worldwide transportation requirements, with disassembly (T) and requiring the fewest permits. All FOL vehicles shall be highway transportable and self-loading onto the M870 series / semi-trailer, which has a deck height of 42”, while meeting worldwide transportation requirements, with disassembly (T) and requiring the fewest permits. If disassembly, collapsing or removal of the cab is necessary, preparation time for trailer transport, or reassemble time after trailer transport, must be accomplished in one hour or less by two people. Thirty minutes or less by two people is desired. Removal of the cab, if required, must be accomplished with equipment organic to the unit. The use of BII only is desired. Transportation by trailer while fully assembled without permits is desired.

3.3.4 Air transportability. The Light loaders, in their shipping configuration, shall be capable of being driven onto C-130 and C-17 aircraft with operator in the driver’s seat.

MIL-HDBK-1791 is available for guidance. The Heavy Loaders, while fully operational shall be capable of being driven onto C-5 or C-17 aircraft with operator in the driver’s seat. MIL-HDBK-1791 is available for guidance. Removal of the ROPS/FOPS cab is allowed provided the loader remains operational. The FOL vehicles shall be air transportable while filled to a minimum 25 percent, up to a maximum 75 percent, fuel capacity. Preparation time for air transport of all FOL vehicles, or reassemble time after air transport, must be one hour or less by two people (T). Thirty minutes or less by two people is desired. C-130 and C-17 air transport while fully assembled is desired for the Light Loaders Type I/II. The capability to accomplish the air transport requirement with the loader fully assembled is desired for the Heavy Loaders Type I/II.

3.3.4.1 Airdrop. The Light Type I loader shall be capable of being airdropped from C- 130 aircraft without breakage or permanent deformation of any structural member or component, or loss of the Loaders ability to perform all functions specified herein. With ROPS/FOPS cab removed/collapsed and while still operational, the loaders shall be capable of being loaded and rigged onto an air delivery platform. Deflation of tires or removal of tires and rims is not permissible to reduce height. The Loader shall be capable of disassembly into LVAD configuration in one hour or less, 30 minutes or less is desired. LVAD while fully assembled is desired. If disassembly is required for LVAD, the loader shall be capable of re-assembly, after LVAD, once the cab arrives at the same location as the base vehicle and a crane/MHE is present, in two hours.

Reassembly in 30 minutes is desired. The loader shall be transportable while filled to 75 percent fuel capacity. MIL-HDBK-669 can be used as a guide for determining impact forces resulting from airdrop. Although not a requirement of this document, the government will rig and drop in accordance to the design requirements defined in MIL-

HDBK-669.

3.3.4.2 Helicopter transport. The (Light Type I only) loader shall meet the requirements of MIL-STD-209 and MIL-STD-913 for helicopter transport. The loader shall be capable of being transported externally from a CH47 helicopter at an altitude of 4,000 ft over 30 nautical miles. In no more than two lifts (a single lift is desired) the loader weight shall not exceed 16,644 lbs. per lift when transported while filled to 75 percent fuel capacity.

It is desired that preparation for travel not exceed one hour.

3.3.4.3 Parachute suspension provisions. Four integral suspension provisions conforming to MIL-STD-814 shall be furnished on the Light Type I loader only. The parachute suspension provisions shall withstand the stresses in the amount and direction of pull specified without weld failure or permanent deformation of the FOL or the provisions. The parachute suspension provisions shall be labeled “ATTACH DROP PARACHUTE HERE” in 0.5 inch letters.

3.3.5 Tie-down provisions. All Loaders shall have four tie-down provisions conforming to the strength requirements of MIL-STD-209. The airdrop platform requirements of MIL- STD-814 shall also be met for the Light Type I. The tie-down provisions shall satisfactorily complete the pull testing as specified without weld failure, permanent deformation, cracking, loosening, or breaking of the provision or its connecting structural components.

3.3.6 Slinging Provisions. All Loaders shall have slinging provisions conforming to MIL- STD-209, Type I. The provisions shall enable the complete FOL to be lifted in the normal operating position. The provisions shall be located so that not less than one-inch clearance is maintained between slings and all exterior parts. The use of spreader bars is not permitted. The provisions shall be fastened to or integral to members which will withstand stresses in the amount and direction of pull specified for the provisions without weld failure, permanent deformation, cracking, loosening, or breaking of the provision or its connecting structural components. Slinging provisions may also be used as tie-down provisions when such provisions meet the requirements specified in 3.3.5.

All slinging/tie-down provisions shall be labeled “LIFT”, “TIEDOWN” or “LIFT TIEDOWN”, as appropriate, in 1-inch (2.54 cm) high letters. For the Light Type I loader only, parachute suspension provisions may be used as slinging provisions if they meet the requirements of MIL-STD-209.

3.3.7 Towing Lugs. The loader(s) shall have towing provisions. The towing lugs shall support one and a half times the loader weight without failure or permanent deformation when the load is applied at an angle of up to 45 degrees from the longitudinal axis. The loader shall have two lugs on the rear that will not create a safety hazard for operator and/or maintenance personnel and shall be in compliance with NATO STANAG 4019.

3.4 Safety. The FOL vehicles shall comply with all applicable commercial or military safety and health hazard standards. The FOL vehicles shall meet all industry and government requirements and design practices to ensure the system optimizes safety during storage; ground, air, and sea transport; air drop; sling loading; maintenance;

operation ground guiding; and disposal. All operator access areas shall be equipped with non-skid decking surfaces and handholds. The FOL shall comply with applicable OSHA 29 CFR 1910 and 1926, and SAE J98, J115, J185 and J1308.

3.4.1 Fire Extinguisher. A fire extinguisher with a minimum rating of 10 B: C shall be securely installed. A fire extinguisher bracket (similar in size and type to NSN 4210-00- 775-0127) shall be provided and mounted in the operator compartment.

3.4.2 Noise limits. The interior operator station noise and exterior noise of the loader(s) shall be below 85-dB when measured in accordance with SAE J1166 and J919. The exterior noise measurement shall be in accordance with J88. Noise data measurements used shall be recorded as required per SAE J88 and J1166. Note: An exchange of 3 dB, in lieu of 5 dB, increase in sound level for halving of the time period shall be applied to the sound level data. If the sound level exceeds 85-dB (A), warning plates containing the following must be permanently affixed to the FOL: “WARNING, HEARING PROTECTION REQUIRED WHEN OPERATING THIS VEHICLE”. The plates located inside the cab as well as outside the cab shall be clearly visible and legible to all personnel exposed to the hazard. For exterior noise measurement, the maximum distance from the loader at which 85-dB (A) is obtained shall be indicated on the noise hazard sign. Manuals shall address noise hazards where appropriate. The plate must have a yellow background with black lettering and shall be on corrosion-resistance material.

3.4.3 Roll Over and Falling Object Protective Structure (ROPS /FOPS). The loader(s) shall be equipped with ROPS conforming to SAE J1040 and FOPS conforming to SAE J231. Quick disconnect fittings (electric, etc.) shall be provided as applicable to facilitate canopy removal. A slinging eye(s) conforming to MIL-STD 209 shall be provided to facilitate removal of ROPS/FOPS as required.

3.4.4 Hazardous materials. The loader(s) shall not contain Class I or Class II ozone- Depleting Substances, asbestos, cadmium (electroplating processes), hexavalent chromium (electroplating, and coatings processes), or other highly toxic or carcinogenic materials as defined in 29 CFR1910.1200 without Governmental approval.

3.4.5 Braking. A braking system conforming to SAE J/ISO 3450 shall be provided. If brake fluid is used, it shall be compatible with MIL-PRF-46176. If the braking system is part of the hydraulic system, the fluid shall be compatible with and operate on fluids conforming to MIL-PRF-46170. The system shall be adequately protected with relief valves. External hydraulic system leakage shall not exceed that indicated for a class 3 system, in accordance with SAE J1176.

SAE J/ISO 3450 covers:

a. A service brake system

b. A secondary brake system

c. A parking brake system

3.4.6 Human factors engineering. The FOL vehicles shall be operable and maintainable in accordance with the recommended practices by 5th percentile female through 95th percentile male military personnel (as defined by SAE J833) dressed in environmental protective clothing (i.e. Arctic and Mission-Oriented Protective Posture (MOPP) IV).

Loader induced vibrations to the operator shall be measured in accordance with SAE J1013.

3.4.7 Back Up Alarm. A backup alarm conforming to SAE J994 shall be furnished. The backup alarm will provide an audible alarm a minimum of 10 dB greater that the surrounding background noise of the operating loader.

3.4.8 Articulation Lock and Lift Arm Support. An articulation lock shall be furnished for all FOL vehicles in conformance with SAE J276. A lift arm support device conforming to the recommendations of SAE J38 shall be provided for the FOL vehicles (Lift arm support removed 6Oct08).

3.5 Survivability The FOL will be High Altitude Electromagnetic Pulse (HEMP)/Near Strike Lightning (NSL)/Electromagnetic Environmental Effects (E3) and electronic warfare/information warfare survivable. This survivability is defined as: the vehicle will be capable of all critical driving and loading operations, in a degraded mode of operation. Operation through a HEMP or NSL event is not required and re-cycling power to restore mission critical functions is acceptable. The design shall conform to the requirements of MIL-STD-461 and MIL-STD-464.

3.5.1 High-Altitude Electromagnetic Pulse (HEMP). The FOL is required to survive a HEMP event during powered down status in shipping, storage and staging deployment configurations, resulting in an operational ready system. During operation, the FOL shall be capable of recycling power after exposure to the high altitude electromagnetic environment as defined in MIL-STD-2169B (classified Secret), with component replacement, within 12 hours. A basic design environment can be found in unclassified form in MIL-STD-464, section 5.5. Verification shall be demonstrated through design, analysis, and/or test. Parts required to make the system operational after a HEMP event shall be identified in the technical manuals.

3.5.2 Nuclear, Biological, and Chemical (NBC) contamination. The FOL components shall be able to operate in an NBC environment and survive decontamination. It is desired that the FOL be capable of being decontaminated to negligible risk levels, with minimum replacements of exposed components. Materials, particularly those used externally, shall be resistant to chemical and biological agents and to the decontaminators used to neutralize these agents. The FOL shall allow for operation by personnel in full protective ensemble (MOPP Level IV). For operator protection, a cab overpressure system is desired for any loader that does not have a removable cab.

NBC decals NSN 7690-01-474-3533 shall be located near the engine and operator station air filters.

3.5.3 Electromagnetic Environmental Effects (E3). The FOL shall comply with the Electromagnetic Radiation Operational requirements in accordance with SAE J551, SAE 1113 and MIL-STD-464 (using TABLE 1D).

3.5.4 Near Strike Lightning (NSL). The FOL is required to survive a nearby lightning strike having the characteristics provided in MIL-STD-464 (using TABLE 2B), that occurs at a distance of 100m.

3.5.5 Natural Environment Threat. The FOL shall be capable of operating in hot, humid tropical environments, in dry, dusty environments and in moderate to cold climate from - 40° F to +120° F (e.g. rain, snow, sleet, dust etc.).

3.5.6 Armor Protection. When specified (See 6.2) the FOL vehicles shall have the capability to provide complete operator protection against blast and fragmentation from munitions as specified in C.15.

3.6 Cab. Windows shall be safety type glass conforming to the guidelines of SAE J674.

Seats in each cab shall be adjustable to accommodate operation by 5th percentile female through 95th percentile male personnel wearing environmental protective clothing (i.e. Arctic and Mission-Oriented Protective Posture (MOPP) IV) in accordance with SAE J899. All plumbing and wires shall have the capability of quick disconnect.

Removable components shall have lift provision IAW with MIL-STD-209 to facilitate cab or component removal. The Light Type II, Heavy Type I and Heavy Type II cabs shall be equipped with all manufacturers’ commercial features, to include as a minimum: air conditioner, heater, defroster, internal and external mirrors and electrically operated windshield wiper(s). These commercial features for the cab are desired for the Light Type I without sacrificing the Low Velocity Air Drop (LVAD)/sling load capability and damage to features. A closed circuit camera system shall be provided to increase operator awareness of surroundings. An electric or air horn shall be provided.

Provisions shall be installed on the FOL to hold Load Bearing Equipment (LBE), Mission-Oriented Protective Posture (MOPP) and Chemical Protective Suit (CPOG).

Inside the cab is desired. Provisions shall be placed as not to interfere with operator view.

3.6.1 Air conditioner. The air conditioning system shall be capable of operating in the cooling mode at ambient temperatures between 65° F and 120° F and shall meet the cooling requirements of SAE J1503. The system shall use an environmentally friendly refrigerant (R-134a or equivalent).

3.6.2 Heater. The heater shall be capable of warming the cab from -25oF to +41oF within an hour after starting the loader when the exterior ambient temperature is at - 25oF. The heater shall meet the heating requirements of SAE J1503.

3.6.3 Instrumentation. The instrument panel shall contain at a minimum the manufacturer's standard array of controls and instrumentation including those necessary to operate options and attachments. Protection from weather elements shall also be provided.

3.6.4 Controls. Each control shall conform to SAE J898. All loader controls shall be located in the operator’s compartment. Mechanical push-pull remote controls, when furnished, shall be waterproof, heat-resistant, and anti-friction. A single keyless engine switch shall be provided. The switch shall control all electrical monitors and electrical equipment, except the horn and lights.

3.6.5 Bucket Positioning. The FOL shall be provided with an automatic boom return to carry and height kick-out. Bucket return to dig position is desired.

3.6.6 Seat. The seat, per SAE J899, shall be located to provide maximum unobstructed visibility for the operator, fully suspended with both armrests and backrest, and provided with retractable seat belts per SAE J386.

3.7 Maintainability. A means shall be made for ease of adjusting, servicing, or replacing parts and components, and shall conform to the recommendations of SAE J925. Articulation locks shall be furnished for all FOL vehicles in conformance with SAE J276. The operator’s daily preventive maintenance checks and service (PMCS) on the FOL shall not exceed 30 minutes for each interval, i.e. 30 minutes before checks, 30 minutes during checks, and 30 minutes after checks.

3.7.1 Fluid drains. The loader(s) shall have an oil change system for quick service of the engine.

3.7.2 Embedded Diagnostic Capabilities. The system shall have embedded diagnostics IAW 3.2.7.1 and 3.2.7.2 or 3.2.7.3 when Line Replacement Unit (LRU) fault isolation capability is equivalent or greater than sections 3.2.7.1 and 3.2.7.2. In addition when practical, the FOL shall have the diagnostic ability to identify major system LRU failures (e.g. check engine lights, blinking / flashing lights etc.).

3.7.2.1 Electronic. The vehicle systems must be compatible with current U. S. Army Standard Unit Level Test Equipment which is presently the MSD (Maintenance Support Device), with the auxiliary MSD-ICE (Internal Combustion Engine) test hardware. Vehicle diagnostic connectors and circuits must be compatible with current standard Army test equipment. Vehicle diagnostic connectors shall be easily accessible, hard mounted and environmentally protected. The diagnostic connectors shall be equipped with a cover, which shall prevent entrance of moisture and contaminants.

The vehicle shall feature either a single data bus network as specified by SAE J1939, J1708, or a multiple data bus network in accordance with J1939, which defines the interface between J1708 and J1939. The vehicle's data bus shall have built in sensors that provide fault isolation capability sufficient to identify failures of major components of each system monitored by the data bus. Diagnostic outputs shall be transmitted to the vehicle mounted J1939 female 9 pin Deutsch Connector, which shall conform to SAE J1939-13 'Off-board Diagnostic Connector' dated July 1999, using a format conforming to SAE J1587. Software required to interface, retrieve, and interpret vehicle system’s diagnostic data shall be provided to the government. Software shall be capable of displaying operator / driver informational data associated with each error code.

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3.7.2.2 Analog. The loaders shall have installed a vehicle Diagnostic Connector Assembly (DCA) harness that will allow testing a vehicle without disassembly IAW the Design Guide For Vehicle Diagnostic Connector Assemblies (DCA) Report No. CR-82- 588-003 Rev 1, Feb 1998.

3.7.2.3 On-board. The FOL shall have an on-board display screen capable of retrieving and interpreting diagnostic error codes of major components of each system monitored by the data bus. The vehicle shall feature either a single data bus network as specified by SAE J1939, J1708, or a multiple data bus network in accordance with J1939, which defines the interface between J1708 and J1939. The vehicle's data bus shall have built in sensors that provide fault isolation capability sufficient to identify failures of major components of each system monitored by the data bus. Diagnostic outputs shall be transmitted to a vehicle mounted RS232 communications port. Software required to interface, retrieve, and interpret vehicle system's diagnostic data shall be provided to the government. Software will also be capable of displaying operator / driver informational data associated with each error code. Software will be capable of performing a self-test of its self.

3.8 Electrical System. The FOL shall be equipped with the contractor’s standard commercial 24-volt negative ground electrical system in accordance with SAE J821 and J1908. The electrical circuitry, including all components and connections, except as specified below, shall be protected from the effects of fungus growth and moisture:

a. Components or circuit elements that are inherently fungus and moisture resistant or which are hermetically sealed need not be treated.

b. Components or circuit elements whose functions will be adversely affected by fungus preventative and moisture coating shall not be treated.

3.8.1 Batteries and cables. The batteries shall have sufficient cold cranking amperage to start the Loader(s) at -40oF. An arctic cold weather starting aid kit is allowable for starting and operating in the temperature range of –25o to -40o F. Battery cables shall be furnished with insulated terminal covers. Positive and negative cable terminals shall be identified with a red sleeve labeled “+” and a black sleeve labeled “-“, respectively.

Corrosion resistant bolts and nuts will be provided. There shall be a warning plate, attached by screws, bolts, or rivets in a conspicuous protected location, on the box to warn of the presence of toxic fumes and the explosive hazards. The batteries shall be easily accessible without the use of tools.

3.8.2 Slave receptacle. The loader(s) shall be equipped with a 24-Volt slave receptacle conforming to NATO STANAG- 4074, Type 1. The slave receptacle shall permit charging of the batteries and slave starting of the engine from an external power source and shall also provide a power source for charging and slaving other equipment. The receptacle shall be installed on the exterior of the loader near the battery enclosure and shall be accessible to personnel standing on the ground. The receptacle shall be labeled "SLAVE 24 VOLTS DC" with one inch black lettering.

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3.8.3 Work lights. The loader(s) shall be furnished with manufacturer’s standard commercial working lights. As a minimum, two overhead lights shall be mounted on the front and two on the rear. All work lights shall be brush-guard protected. They shall be adjustable and located to illuminate maximum work area.

3.8.3.1 Blackout Lighting. The FOL shall be furnished with one head and two tail/ stop blackout lights conforming to MIL-STD-1179. An interior switch conforming to MS 51113, which is readily accessible to the operator in his seated position, shall control the blackout lights. All other exterior lights, backup alarm, closed circuit camera system and the horn, if electric, will be made inoperable automatically when the blackout lights are switched on. The blackout mode switch shall activate all blackout lights and markers.

3.8.3.2 Turn Signals and Emergency Flashers. The Loaders shall be equipped with turn signals and emergency flashers. All lights shall be controlled from the operator's compartment.

3.9 Powertrain.

3.9.1 Hydraulic Reservoir. Hydraulic tank oil temperature shall not exceed 200°F with an ambient temperature of 120°F while performing sustained digging operations. A hydraulic oil drain petcock valve located at the lowest point of the tank or vehicle hydraulic system shall be furnished.

3.9.2 Automatic ride control. The loader(s) shall be provided with an automatic ride control system that once initiated by the operator, if the loader starts to pitch, the ride control system automatically compensates.

3.9.3 Steering. The loader shall have a primary and secondary steering system per SAE J1511. The loader shall have a steering lock as per SAE J276.

3.9.4 Tires. The threshold requirement for the FOL tires is standard bias tires, with an objective of standard tubeless radial tires. Tires shall be deep rock type tread with a L4 rating for Heavy Type I, a L3 rating for Heavy Type II Loaders and traction type tread with a L2 rating for Light Type I and II Loaders. The tires selected by the manufacturer shall be of sufficient rating to perform all operations to full capacity of all attachments required within this procuring document, without exceeding the Tire and Rim Association’s (TRA) recommendation for the tire application. The Tire and Rim Association Yearbook recommended tire pressure marking shall be stenciled as “TP (specify) LBS” in 1-inch high letters above or adjacent to each tire. If a multi-piece split rim is used, the side flange (solid rim ring) must completely capture the lock ring (split ring) when air is applied to the tire but before building of pressure in the tire. The lock ring should be either symmetrically designed for installation in either direction, or if not symmetrical, designed so reverse installation is not physically possible or prevents tire inflation by not allowing the flange to properly seal. The tires shall not be more than four calendar quarters in age from date of acceptance by the Government.

3.9.5 Axles. The loader(s) shall have a positive 4 wheel drive axle system to provide traction. When a wheel loses traction, the axle 1) shall automatically transfer drive power to the other wheel or 2) the operator manually engages, from the cab, a positive traction system. This positive traction system shall be provided for either the front or the rear axles.

3.9.6 Engine. The diesel engine provided shall have an EPA emission certification for non-road diesel engines as required by 40 CFR Parts 89, and 1039, at its power rating.

The diesel engine shall have the capability for an unassisted –25°F cold start and operate with diesel fuel oil and aviation, kerosene type turbine fuel, grade JP-8. When specified (See 6.2), the loader shall be provided with an arctic cold weather starting kit that shall allow the loader to start and operate at temperatures from -25 degrees F to - 40 degrees F. No cold weather starting aid may be used which rely upon external support such as an electrical power source. Hand-held aerosol cans or non-metered starting fluid devices are not permitted. The engine’s emergency shut off handle shall be easily accessible and clearly visible.

3.9.6.1 Fuel Tank. The fuel tank shall have sufficient capacity for 10 hours of continuous normal operation for all specified fuels. The fuel line shall be equipped with a commercial fuel/water separator. The tank shall be equipped with a means for draining water and sediment from the bottom of the tank. The fuel tank interior surface shall be permanently protected from corrosion. The fuel type shall be stenciled near the fuel cap in black letters not less than one inch in height. The fuel tank filler necks shall have a removable screen.

3.10 Lubricants. Lubrication means shall be provided for all moving parts requiring lubrication. All FOL vehicles shall be operable using military lubricants. Initial fill lubricants shall fully conform to the following requirements:

a. Engine: MIL-PRF-2104 and MIL-PRF-46167

b. Hydraulic systems: MIL-PRF-46170

c. General lubrication: MIL-PRF-10924, SAE-AMS-M-7866 and MIL-PRF-23827 (When cold starting kit is required).

d. Axles: MIL-PRF-2105.

3.10.1 Lubrication data plates. A lubrication data plate shall be provided (attached by screws, bolts, or rivets in a conspicuous protected location) and conform to SAE J753.

The plate shall identify military lubricants and all lubrication points.

3.10.2 Lubrication fittings. Fittings shall be located in a protected, accessible location.

Fittings shall be accessible to a grease gun with a 10 inch flexible extension. Fittings shall be accessible without removing or adjusting accessories or parts. Extended lubrication points shall be used for hard to reach areas and be accessible to an operator standing on the ground.

3.10.3 External Leakage. The degree of external hydraulic system leakage allowable on all loaders shall not exceed class 3 of SAE J1176 for dust free conditions and class 3D of SAE J1176 for dusty conditions. The degree of external leakage allowable on drive-train components such as engine, axles, transmission, transfer cases, and gearboxes shall not exceed class 2 of SAE J1176 for dust free conditions and class 2D of SAE J1176 for dusty conditions. No evidence of fluid leakage shall be permitted in fuel, cooling or hydraulic brake systems.

3.10.4 Oil Sampling Valves. Oil sampling valves shall be provided on the engine, transmission and hydraulic system. The valves shall be manually operated and shall automatically close when released. It shall be made of material resistant to corrosion such that it will not contaminate the sample. The discharge port of the valve shall be covered with a captive chain cap conforming to MIL-V-81940/1B and SAE J514. The valve shall be located in such a way as to insure that the personnel will not be exposed to danger.

3.11 Additional Features.

3.11.1 Tool/Storage box. A weatherproof, lockable tool/storage box shall be provided on each loader that shall be of sufficient size to accommodate the necessary tools and BII items to perform operator services and maintenance and shall be above the fording depth. The box cover shall be secured using a padlock eye minimum size 0.375 inches.

A means for draining the box shall be provided.

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