Attachment 0007 ATPD 2358 - Grader-Road_Motorized.pdf

ATPD 2358

29 May 2009

PURCHASE DESCRIPTION

GRADER, ROAD, MOTORIZED,

DIESEL-ENGINE-DRIVEN, SECTIONALIZED

AND NON-SECTIONALIZED

1. SCOPE

1.1 Scope. This purchase description covers the sectionalized and non-sectionalized motor graders.

1.2 Classification. The graders shall be of the following types, as specified (see 6.2):

Type I – Non-sectionalized (C-130 Transportable).

Type II – Sectionalized (C-130 Transportable, Air-droppable, and CH-47

Helicopter Transportable).

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.

1.4 Armor Considerations. Except where noted, all criteria shall be met in the armor A-kit configuration (see 3.6.6).

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 or from their website at ht t p : / / a ss is t . d ap s . d la . mi l ).

http://assist.daps.dla.mil/

FEDERAL

FED-STD-595 Colors Used in Government Procurement

A-A-50271 Plate, Identification

A-A-52513 Bracket Assembly, Liquid Container, Five Gallon

A-A-52624 Antifreeze, Multi Engine

A-A-59592 Can, fuel, Military: 20-Liter Capacity

MILITARY

NATOSTANAG-2828 Military Pallets, Packages and Containers

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-DTL-83133 Turbine Fuel, Aviation, Kerosene Type JP-8 (NATO F-34, NATO F-35).

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-10924 Grease, Automotive and Artillery

MIL-PRF-11021 Switch, Vehicular Lights, 24 Volt DC

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-1180 Safety Standards for Military Ground 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

2.1.2 Other Government documents drawings, and publications.

U.S. ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND (TACOM)

DRAWINGS

ME 13229E8014 and 13229E8016 - Bracket Assembly Rifle Stowage

MS500048 - Towbar, Motor Vehicle: Light, Medium And Heavy Duty

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 SURFACE DEPLOYMENT AND DISTRIBUTION COMMAND

TRANSPORTATION ENGINEERING AGENCY (SDDCTEA)

SDDCTEA PAMPHLET 70-1 – Transportability for Better Deployability

(Application for copies should be addressed to the Military Surface Deployment and Distribution

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 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).

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 3449 Earth-Moving Machinery - Falling-Object Protective Structures - Laboratory

Tests and Performance Requirements

ISO 3450 Earth-Moving Machinery - Braking Systems of Rubber-Tyred Machines -

Systems and Performance Requirements and Test Procedures

ISO 3471 Earth-moving machinery Roll-over protective structures Laboratory tests and performance requirements

(Application for copies should be addresses to American National Standards Institute, 11 West nd

Street, New York, NY 10036.)

SOCIETY OF AUTOMOTIVE ENGINEERS, INC (SAE)

AMS-M-7866 Molybdenum Disulfide, Technical, Lubrication Grade

J98 Personnel Protection for General Purpose Industrial Machines

J115 Safety Signs

J185 Access Systems for Off-Road Machines

J276 Steering Frame Lock for Articulated Loaders and Tractors

J336 Truck Cab Interior, Sound Level for

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

J753 Lubrication Chart - Construction and Industrial Machinery

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

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

J1074 Engine Sound Level Measurement Procedure

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

J1308 Fan Guard for Off- Road 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

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

J2360 Lubricating Oil, Gear Multipurpose (Metric) Military Use (previously MIL-

PRF-2105).

(Application for copies should be addressed to the Society of Automotive Engineers, Inc., 400

Commonwealth Drive, Warrendale, PA 15096.)

3. REQUIREMENTS

3.1 General. The grader shall be the latest model of the standard product of the contractor and shall have demonstrated industry acceptability by having been manufactured, marketed, and sold in significant numbers to the commercial public for the same or similar application, interfacing with the same or similar components, except as specified herein, for at least 1 year prior to invitation for bids or request for proposal. Product improvements incorporated in the commercial production units in this 1 year period are acceptable. In the case of a recently introduced item, the contractor shall submit sufficient valid industrial operational/test data including all test reports for the item and its components, such as; engine, transmission and hydraulic system, field user reports, including any failures or problem areas, and corrective action taken to demonstrate acceptability of the item. When specified requirements are not stated herein, all items listed as standard equipment in the contractor’s published specification brochures and catalogues, or normally furnished to commercial customers as standard equipment, shall be furnished. The grader shall be equipped with any optional equipment necessary to comply with requirements specified herein. Optional equipment is defined as equipment not standard with the grader but which has been furnished to the commercial customer, such as special features or allied equipment. The grader shall be equipped with all components necessary to enable the grader to function reliably and efficiently and shall operate with the fuels and lubricants as required herein. Manufacturer decals, logos and model numbers shall not be displayed on the grader. The grader shall conform to all Federal Law and regulations governing safety and noise levels which are in effect on the date of proposal or publicly known to be scheduled for implementation during the performance of the contract.

3.2 Description. The grader shall be a pneumatic-tired, diesel-engine-driven, 6-wheeled, all-wheel drive, commercial construction grader. Three methods of steering shall be provided:

front wheel steer, leaning front wheels, and articulated frame steering. The grader shall be equipped with a power shift transmission, a 12-foot moldboard, and a V-type scarifier. The grader shall be operable by one man for general construction work such as coarse and fine grading, low and high bank sloping, flat and V-ditching, scarifying, snow removal and general road maintenance. The grader shall permit true “sit down” operation with operator seated and seat belt properly fastened. The grader shall be equipped with a hydraulic system for operation of attachments specified in 3.2.6 as appropriate.

3.2.1 Type I. The type I grader with ROPS/FOPS removed shall be capable of being transported by C-130, C-5 and C-17 military aircraft.

3.2.2 Type II. The Type II Graders shall be identical to Type I with different transportability requirements as defined herein. The type II grader with ROPS/FOPS removed shall meet the requirements specified for type I (see 3.2.1), be capable of airdrop from C-130 aircraft (loaded and rigged on an air delivery platform in accordance with MIL-HDBK-669) and capable of being sectionalized into two sections for external air transport by CH-47 helicopter.

3.2.3 Weight limits. Axle loads and maximum weight must comply TEA Pamphlet 70-1 when configured for C-130E/H transport. In order to accommodate C-130 transport, no axle load shall exceed 13,000 lbs. and the overall vehicle weight shall not exceed 42,000 lbs. The type II grader without the ROPS/FOPS, scarifier, and sectionalization kit, but with all other attachments, accessories, coolant, lubricating and hydraulic systems filled to capacity and with not less than 25 percent nor more than 75 percent fuel shall weigh no more than 30,600 pounds.

If the grader exceeds 30,600 lbs. the contractor shall prove that the machine can be rigged for airdrop with a total rigged weight of 40,000 lbs. or less. The type II grader when sectionalized shall not weigh more than 16,644 pounds per section.

3.2.4 Dimensions. The most restrictive transport mode for the grader is C-130E/H aircraft transport. Reference “Transportability for Better Deployability” TEA Pamphlet 70-1 for specifics.

3.2.4.1 Type I. The overall width of the grader shall not exceed 102 inches, except that the width may be increased to not more than 105 inches to accommodate special airborne/airmobile provisions. The overall length shall be driven by the C-130 Roll-On/Roll-Off

(RORO) requirement (See TEA Pamphlet 70-1 for guidance), not to exceed 468 inches. Overall height when configured for C-130 RORO shall not exceed 102 inches.

3.2.4.2 Type II. The overall width of the grader shall not exceed 102 inches, except that the width may be increased to not more than 105 inches to accommodate special airborne/airmobile provisions. The overall length shall be driven by the C-130 airdrop requirement (See MIL-STD-814 for guidance), not to exceed 384 inches. In order to conform to a height limit of 100 inches when rigged for airdrop, the reducible height of the grader should be not more than 91 inches. No major component removal except the ROPS/FOPS canopy shall be required to obtain the reduced height. If the height exceeds 91 inches, the contractor must demonstrate prior to step I of the proposal opening date that his grader can be rigged so as to conform to the 100 inch limit, and withstand the forces encountered in the simulated airdrop impact test (see 4.3.6.5) without damage or permanent deformation.

3.2.5 Sectionalization. The type II grader, less ROPS, shall be capable of being sectionalized into two sections for helicopter transport. The weight of either section shall not exceed 16,644 pounds. The powered section shall be driveable and steerable under its own power for a distance of 50 feet over relatively flat unimproved areas. Reassembly time with tools furnished with the grader under field conditions and without assistance of other powered equipment shall not exceed 4 hours. Cutting and welding are not permitted. Components and accessories used in sectionalization and reassembly shall be stored in separate, helicopter slingable container or attached to the grader but shall not interfere with the operation of the grader.

3.2.6 Attachments.

3.2.6.1 Blade. The blade assembly shall be 12 foot in length. It shall consist of a wear-resistant moldboard and replaceable cutting edges and shall have hydraulic sideshift and hydraulic tilt.

3.2.6.2 Scarifier. The grader shall be equipped with a V-type scarifier. The scarifier shall be equipped with removable shanks having replaceable points. On-board storage for the removable shanks shall be provided. The scarifier shall have not less than 9 shanks and a swath of not less than 46 inches.

3.2.6.3 Blade Leveling. The grader shall be pre-wired for operation with a device which aids in blade leveling or final grading operations (i.e. laser or GPS).

3.3 Performance. The grader shall have six wheels with all-wheel drive. The grader and attachments shall withstand the usage encountered in military operations such as rough and fine grading, ditching, high bank cutting and sloping, grading in reverse and scarifying. The grader shall withstand crossing rough terrain, including gullies causing the tandems to oscillate in both directions, fording streams, and negotiating steep longitudinal and side slopes, without damage.

The grader shall be capable of being towed by another vehicle and limited towing of other equipment.

3.3.1 Operating Temperatures The grader shall be capable of operating in hot and basic climate regions (+120° F to -25° F). The grader shall be capable of starting, without external starting aids, within 10 minutes and operating under full-load conditions within thirty minutes after engine start. An arctic cold weather starting aid kit, (See 3.10.4.1), may be used for starting and operating in cold regions from -25° F to -40° F.

3.3.2 Travel speed. The grader shall be capable of a forward travel speed of not less than

20 mph on level pavement (30 mph desired).

3.3.3 Blade pull. Calculations shall show that the grader shall develop a blade pull of not less than 16,000 pounds (required), 32,000 pounds (desired) at 2 plus or minus ½ MPH, at the specified operating weight, on a dry, level, concrete surface (tire traction coefficient=.90), in all-wheel drive mode with no wheel slip both with and without B-kit installed.

3.3.4 Stability. The grader shall negotiate 30% side slope (required)/35% (desired) and

50 percent longitudinal slopes without any wheel of the grader losing contact with the ground

(with the blade and scarifier in the fully raised position, with no frame articulation). With the B-kit installed, the grader shall negotiate 15% side slope (required)/35% (desired) and 50 percent longitudinal slopes without any wheel of the grader losing contact with the ground (with the blade and scarifier in the fully raised position, with no frame articulation). All parts requiring lubrication shall be lubricated when the grader is operating under these conditions.

3.3.5 Fording. The grader shall start and operate during and after fording operations in fresh water to any depth up to 30 inches including wave action without damage and without leakage of water into reservoirs containing lubricants.

3.3.6 Blade lift. The blade shall have a lift above ground level of not less than 16 inches.

3.3.7 Blade cut. The blade shall have a cut below ground of not less than 10 inches.

3.3.8 Blade reach. The blade shall have a reach (right/left) of not less than 6 feet outside the rear tires.

3.3.9 Bank cutting angle. The blade shall have a right/left bank cutting angle of 90 degrees.

3.3.10 Circle turn. The blade shall be capable of traversing 360 degrees without removing any machine components other than the scarifier shanks by utilizing controls at the operator’s station.

3.4 Transportability Requirements. The grader shall be capable of being transported worldwide by rail, marine, highway, and air modes. Guidance on transportability criteria is defined in MIL-STD-1366 and TEA Pamphlet 70-1. If disassembly is required to meet any of the transportation requirements, it shall be disassembled in 30 minutes (15 minutes desired) or less, by two soldiers, with on board tools and BII. Reassembly in 60 minutes (10 minutes desired).

No disassembly is desired. Disassembly by use of cutting/welding equipment is NOT allowed.

3.4.1 Rail Transport. The grader shall be rail transportable in CONUS and NATO countries without restrictions. Reference MIL-STD-1366 and TEA Pamphlet 70-1. The grader 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 grader 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 grader 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 grader vehicles shall be transportable by rail with disassembly in 30 minutes (15 minutes desired) or less, by two soldiers, with on board tools and BII. Reassembly in 60 minutes (10 minutes desired). No disassembly is desired. Disassembly by use of cutting/welding equipment is NOT allowed

3.4.2 Marine transport. The grader 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 grader 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.

3.4.3 Highway transport. The graders shall be highway transportable and self-loading onto the M870 series semi-trailer (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 30 minutes (15 minutes desired) or less, by two soldiers, with on board tools and BII. Reassembly must be accomplished in 60 minutes (10 minutes desired). No disassembly for trailer transport is desired. Disassembly by use of cutting/welding equipment is NOT allowed

3.4.4 Air transportability. The graders, in their shipping configuration, shall be capable of being driven onto C-130, C-5 and C-17 aircraft with operator in the driver’s seat. MIL-

HDBK-1791 and TEA Pamphlet 70-1 are available for guidance. Removal of the ROPS/FOPS cab is allowed provided the grader remains operational. The grader shall be air transportable while filled to a minimum 25 percent, up to a maximum 75 percent, fuel capacity. On-tarmac preparation time for air transport of grader must be thirty minutes or less by two people using BII

(T). Major component removal such as ROPS/FOPS, hydraulic cylinders, etc. removed off-tarmac are not included in the time requirement. Grader must remain drivable after major component removal. Reconfigure time for system using two people and BII in 60 minutes or less (T).

3.4.5 Airdrop. The Type II grader 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 Grader’s ability to perform all functions specified herein. With ROPS/FOPS cab removed/collapsed and while still operational, the graders shall be capable of being rigged and loaded onto an air delivery platform. The Grader shall be capable of being disassembled into

LVAD (Low Velocity Air-Drop) 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 grader 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. 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.

3.4.6 Helicopter transport. The Type II grader shall meet the requirements of MIL-STD-

209 and MIL-STD-913 for helicopter transport. The grader shall be capable of being transported externally from a CH-47D helicopter at an altitude of 4,000 ft over 30 nautical miles in no more than two lifts. The weight shall not exceed 16,644 lbs. per lift while filled to 75 percent fuel capacity. It is desired that preparation for sling lift not exceed one hour.

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

3.4.8 Tie-down provisions. All graders shall have four tie-down provisions, to permit tiedown of the grader to the floor or deck of the transportation medium or the airdrop platform.

The vehicle weight to be used when calculating the required strength of the tie-downs shall include the armor solution and all attachments. The tiedown provisions shall conform to MIL-

STD-209 and MIL-STD-814 and shall withstand stresses in the amount and direction of pull specified without weld failure, permanent deformation, cracking, loosening, or breaking of the provision or its connecting structural components. If stenciling cannot conform to MIL-STD-

209 due to space limitations, government approval is required on alternate stenciling.

3.4.9 Slinging Provisions. All graders shall have slinging provisions conforming to MIL-

STD-209, Type I. The provisions shall enable the complete grader, and sectionalized pieces (if applicable), including CPK components, 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 3.4.8.

All slinging/tie-down provisions shall be labeled “LIFT”, “TIEDOWN” or “LIFT TIEDOWN”, as appropriate, in not less than 1-inch (2.54 cm) high letters. For the Type II graders only, parachute suspension provisions may be used as slinging provisions if they meet the requirements of MIL-STD-209.

3.4.10 Towing Lugs. Two vehicular towing lugs shall be furnished and shall provide clearance to connect a towbar conforming to MS500048, medium-duty capacity. The lugs shall be installed between 17 to 21 inches on each side of the vehicle centerline, on the front of the vehicle. Each towing lug and its mounting shall withstand a load of at least 70 percent of the vehicle's curb weight (including armor kit), without failure or permanent deformation when the load is applied at an angle of up to 45 degrees from the longitudinal axis. The grader 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

3.5 Safety. The grader vehicles shall comply with all applicable commercial or military safety and health hazard standards. The grader vehicles shall meet all industry and government requirements and design practices to ensure the system optimizes safety during storage; ground, air, and sea transport; maintenance; operation ground guiding; and disposal. All operator access areas shall be equipped with non-skid decking surfaces and handholds. The grader shall comply with applicable OSHA 29 CFR 1910 and 1926, and SAE J98, J115, J185 and J1308.

3.5.1 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.

3.5.2 Noise limits. Steady-state noise produced by the grader shall not exceed 85 dB(A), for sustained exposure, as measured in 4.3.7.1. If it does not, and remedial procedures for noise suppression have been pursued to the satisfaction of the procuring activity, and permission to exceed the limit(s) is obtained, then hazard signs shall be provided. At a minimum, each sign shall state “HEARING PROTECTION REQUIRED WITHIN (specify) FEET FOR

PROLONGED EXPOSURE” and shall be legible from the distance indicated on the sign both with and without CPK installed. Steady state interior noise level at cab seating position shall not exceed 85 dB(A) when tested in accordance with 4.3.7.1.

3.5.3 Roll Over and Falling Object Protective Structure (ROPS /FOPS). The grader, in

A-kit configuration, shall be equipped with ROPS conforming to ISO 3471 and FOPS conforming to ISO 3449. Quick disconnect fittings (electric, etc.) shall be provided as applicable to facilitate canopy removal. Slinging eyes conforming to MIL-STD 209 shall be provided to facilitate removal of ROPS/FOPS as required. ROPS certification with armor kit installed is desired.

3.5.3.1 The up-armored Grader with CPK installed shall meet the same FOPS requirements as the base vehicle, i.e., paragraph 3.5.3. The The contractor shall perform the following in an effort support the government's risk assessment analysis of the Grader with the CPK installed. To demonstrate that the ROPS protects the operator, the contractor shall test the ROPS, with CPK installed without the transparent armor, IAW ISO 3471. Test to be performed as follows:

TEST 1: Perform load testing only per ISO 3471. Load ROPS to the ISO minimum in the lateral, longitudinal and vertical directions.

TEST 2: Perform load and energy testing per ISO 3471. Load ROPS in lateral direction per ISO, if energy is achieved, repeat the longitudinal and vertical force tests.

3.5.3.2 The contractor shall provide a final test report outlining the results to the government The test report shall be provided in contractor standard format and include the following information:

Objective of test

Per ISO 3471, List the equation used to determine the loading and energy requirements from table 1

Outline what the load and energy requirements are determined to be

List the total vehicle weight used to determine the load and energy requirements

Pictures/Diagrams of loading configurations

Maximum load achieved

Maximum energy absorption achieved

Maximum deflection and permanent deflection

Force deflection curves shall be provided for each required load configuration

Conclusion of test

Contractor shall deliver ROPS report within 2 weeks of test completion. The government will review the report. The contractor will make any corrections within five days of receipt of government review.

3.5.4 Hazardous materials. The grader 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 shall not be used in the manufacture or assembly of the Grader without Governmental approval. These requirements shall apply to any components/parts purchased through a subcontractor/vendor.

3.5.5 Braking. A braking system conforming to SAE J/ISO 3450 both with and without

CPK installed 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.

SAE J/ISO 3450 covers:

a. A service brake system

b. A secondary brake system

c. A parking brake system/transmission interlock

3.5.6 Human factors engineering. The grader(s) shall be operable and maintainable in accordance with the recommended practices by 5 th percentile female through 95 th percentile male military personnel (as defined by SAE J833) dressed in environmental protective clothing (i.e.

Arctic, body armor and in Mission-Oriented Protective Posture (MOPP) IV). Grader induced vibrations to the operator shall be measured in accordance with SAE J1013.

3.5.7 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 grader. Alarm shall automatically disengage while in blackout drive.

3.5.8 Articulation Lock. An articulation lock shall be furnished for all grader vehicles in conformance with SAE J276.

3.6 Survivability The grader will be High Altitude Electromagnetic Pulse (HEMP)/Near

Strike Lightning (NSL)/Electromagnetic Environmental Effects (E3) survivable. This survivability is defined as: the vehicle will be capable of all critical driving and grading 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.

3.6.1 High-Altitude Electromagnetic Pulse (HEMP). The grader 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 grader 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.

3.6.2 Chemical, Biological, Radiological, Nuclear (CBRN) Contamination. The grader components shall be able to operate in a CBRN environment and survive decontamination. It is desired that the grader be capable of being decontaminated to negligible risk levels, with minimum replacement 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 grader shall allow for operation by personnel in full protective ensemble

(MOPP Level IV). For operator protection, a cab overpressure system is desired for any grader that does not have a removable cab.

3.6.3 Electromagnetic Environmental Effects (E3). The production representative version of the system shall be electromagnetically compatible among all subsystems and equipment within the system and with E3 external to the system. To meet this requirement compliance to

MIL-STD-464 to the extent delineated in the following paragraphs shall be achieved.

3.6.3.1 Intra-system Electromagnetic Compatibility (EMC). The system shall be electromagnetically compatible within itself such that the system operational performance requirements are met. Individual subsystems and equipment shall meet interference control requirements (such as conducted emissions, radiated emissions, conducted susceptibility and radiated susceptibility requirements of MIL-STD-461) such that the overall system complies with MIL-STD-464.

3.6.3.2 Inter-system EMC. The system shall be electromagnetically compatible with its defined Electromagnetic Environment (EME) such that its operational performance requirements are met. The applicable external EME for ground systems is described in MIL-STD-464, Table

1C. Inter-system EMC covers compatibility with, but is not limited to like platforms (such as other graders), friendly emitters, and hostile emitters.

3.6.4 Near Strike Lightning (NSL). The grader 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.

3.6.5 Reserved

3.6.6 Supplemental Armor Set/Crew Protection Kit. The grader shall be provided with a

Crew Protection Kit that provides complete operator protection against direct small arms fire and improvised explosive devices. The CPK shall be provided in the form of a two part “A-kit/B-kit” or “A-kit/C-kit”. The A-Kit consists of permanent mounting provisions along with any vehicle modifications required to accept the armor package (e.g. armored floor panel, suspension changes due to the increased weight of the armor kit, etc.). The A-kit shall be installed during production on every vehicle. The B-kit consists of multiple components that need to be individually installed on the grader. The C-kit consists of a complete interchangeable armored cab. When specified, the grader shall be provided with a CPK (see 6.2).

3.6.6.1 Crew protection armor kit. The grader, with the armor kit, shall provide minimum degradation to performance and maintainability, be easily and quickly installed, and maximize commonality of attaching hardware with no special tools required for maintenance. For maintenance only, the tools required shall be found in the Army General Mechanics Tool Kit, Automotive, (NSN 5180-00-177-7033) and/or other equipment available at unit level. With the armor kit installed, the operator, in a seated position, shall have line of sight to the blade corners during all standard operations. It is required that no component be laden with more than 120% of its rated load with the armor kit installed. The armor kit shall provide a means of emergency egress to allow the operator to escape in case of vehicle roll over in the event that the cab door is inaccessible or inoperable. The CPK shall be designed to provide maximum coverage for the operator. Ballistic gaps that may be necessary to allow pass through routings for items such as driver controls, electrical harnesses and hoses shall be minimized.

It is desired that installation of the armor kit has minimal impact on visibility. It is desired to have a camera installed with the armor kit that will provide sufficient visibility to eliminate the necessity of a ground guide during backing operations and to provide operator visibility of the rear-mounted scarifier (if equipped). Even if a camera is used, direct line of sight visibility must be maintained to the rear of the vehicle in case of camera failure. It is desired that the grader meet the requirements of 3.5.3 ROPS/FOPS after installation of the armor kit.

3.6.6.2 See Addendum 1

3.6.6.3 Crew protection cooling. The vehicle cab, with armor kit installed, shall meet the cooling requirement of 3.7.1. It is desired to meet this requirement with the vehicle’s on-board air conditioning system. If necessary, an auxiliary air conditioning unit may be installed with the add on armor kit. If an auxiliary air conditioner is required, it shall have a high degree of commonality with the air conditioner used in existing Army armor solutions, and the A-kit alternator must have the capacity to support the auxiliary air conditioner.

3.6.6.4 Crew protection kit transportation. The CPK shall be delivered and stored in a container that is new, weatherproof, non-collapsible, lockable, repairable, and suitable for repeated use. The container shall be stackable to two-high (that is one base container with one container on top) when fully loaded to container rated gross weight without damage or permanent deformation. The container shall be configured such that all components of the armor kit are protected during shipment, and to facilitate quick inventory of the contents. When the armor kit is installed on a grader, the container shall store all items removed from the grader to facilitate armor installation. The container shall have forklift pockets that conform to STANAG

2828 that allow the container to be forklifted from all four sides. The containers shall be capable of being transported by military and commercial vehicles, trailers, trains, marine vessels, aircraft, dolly sets and shall withstand the impact forces encountered in shipment without damage or permanent deformation. The containers shall be capable of being transported by C-130, C-5, and

C-17 with or without supporting equipment existing in the DoD system. Container shall be externally transportable by CH-47. The container shall be painted the same color as the armor kit contained within, in accordance with 3.14. For container types existing in the DoD inventory, the modifications performed for this effort shall not void existing certifications.

3.7 Cab. Grader A-kit 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) and body armor in accordance with

SAE J899. Removable components shall have lift provision IAW with MIL-STD-209 to facilitate cab or component removal. The cab shall be equipped with all manufacturers’ commercial features, to include as a minimum: air conditioner, heater, defroster, mirrors and electrically operated windshield wiper(s). These commercial features for the cab are desired without sacrificing the C-130 transportability. An electric or air horn shall be provided. Space shall be available inside the cab to stow Load Bearing Equipment (LBE), Mission-Oriented

Protective Posture (MOPP) and Chemical Protective Suit (CPOG).

3.7.1 Air conditioner. The air conditioning system shall be capable of operating in the cooling mode at ambient temperatures up to 120° F and shall meet the cooling requirements of

SAE J1503 (interior temperature requirement of 80° F). The system shall use an environmentally friendly refrigerant (R-134a or equivalent).

3.7.2 Heater. The heater shall be capable of warming the cab from -25 o F to +41 o F within an hour after starting the grader when the exterior ambient temperature is at -25 o F both with and without the optional armor package. The heater shall meet the requirements of SAE J1503.

3.7.3 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. An inclinometer, indicating frame angle, shall be provided and located within view of the operator.

3.7.4 Controls. Each control shall conform to SAE J898. All grader 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. Joystick control for all blade functions is required; joystick control for all blade functions and steering is desired.

3.7.5 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.

3.8 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. Preventive maintenance checks and services (PMCS) shall be developed for both the operator and field level of maintenance using the principals of Condition Based Maintenance (CBM). The operator level

“before operations” PMCS shall be limited to the mission essential functions to get the end item in operation as quickly as possible. “During operations” checks shall be those which can be easily monitored during equipment operation. The majority of operator checks shall be “after operations” category. Field level PMCS shall consist of periodic scheduled checks and services.

3.8.1 Fluid drains. The grader shall have an oil change system that minimizes spills for quick service of the engine, hydraulics and transmission.

3.8.2 Vehicles Diagnostic Capabilities. The grader shall have diagnostics capabilities that conform to either Option A, IAW 3.8.2.1 and 3.8.2.2 or Option B, embedded diagnostics IAW

3.8.2.3. Option B is preferred when Line Replacement Unit (LRU) fault isolation capability is equivalent or greater than sections 3.8.2.1 and 3.8.2.2. In addition, the grader shall have the diagnostic ability to identify major system LRU failures (e.g. check engine lights, blinking / flashing lights etc.).

OPTION A:

3.8.2.1 Electronic. The grader 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 grader 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 vehicles 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 that is for the MSD 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.

3.8.2.2 Analog. Analog circuitry that cannot be diagnosed using the capability in para

3.8.2, shall require a diagnostic connecter. The grader shall have a vehicle Diagnostic Connector

Assembly (DCA) harness installed 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.

OPTION B:

3.8.2.3 Embedded diagnostics. The grader shall have embedded software and an on-board display screen capable of retrieving and interpreting diagnostic error codes of each LRU of each system monitored by the data bus. The grader 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 diagnostic software and data bus shall have built in sensors that provide fault isolation capability sufficient to identify failures of each LRU. Vehicle software will also be capable of displaying operator / driver informational data associated with each error code. Vehicle software will be capable of performing a self-test.

3.8.3 Reserved

3.9 Electrical System. The grader shall be equipped with a 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.

3.9.1 Batteries and cables. The batteries shall have sufficient cold cranking amperage to start the grader at -25 o F. An arctic cold weather starting aid kit is allowable for starting and operating in the temperature range of –25 o to -40 o 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.

3.9.2 Slave receptacle. The grader 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 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.

3.9.3 Work lights. The grader shall be furnished with the manufacturer’s standard commercial working lights. As a minimum the following lights will be furnished:

(a) Two headlights.

(b) Two front working lights.

(c) Combination stop and taillights.

(d) Turn signals with emergency flasher.

(e) Rear floodlight(s).

(f) Instrument panel lighting.

(g) Blackout lighting.

3.9.3.1 Blackout Lighting. The grader shall be furnished with one head and two tail/ stop blackout lights conforming to MIL-STD-1179. An interior switch conforming to MIL-PRF-

11021 (mechanical style), which is readily accessible to the operator in his seated position, shall control the blackout lights. All other exterior lights, backup alarm 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. Light emitting diode (LED) type black out lights are required.

3.10 Powertrain.

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

3.10.2 Steering. The grader shall have a primary and secondary steering system per SAE

J1511. The grader shall have a steering lock as per SAE J276.

3.10.3 Wheels, tires and axles. The grader shall be equipped with single tire and wheel assemblies on each axle. The wheels shall conform to Tire and Rim Association recommendations for the type and size of tire furnished. If wheels of multi-piece construction are to be used, they must be pre-approved by the contracting officer. All tires shall be identical.

Tires and rims shall meet requirements 119.1 and 120.1 of MIL-STD-1180.