Attachment 001 - ATPD-2332F - M872A4 Vehicle Semitrailer Flatbed - Distro A.pdf

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited.

Beneficial comments, suggestions, or questions on this document should be addressed to U.S. Army Tank-automotive and Armaments Command, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or emailed to dami_standardization@conus.army.mil

ATPD 2332F

7 May 2009

SUPERSEDING

7 January 2005

PURCHASE DESCRIPTION

M872A4 VEHICLE, SEMITRAILER,

FLATBED: DUAL PURPOSE, BREAKBULK/CONTAINER TRANSPORTER,

20/40’ LONG ISO CONTAINER, 34 TON

1. SCOPE

1.1 Scope. This Purchase Description (PD) identifies the performance and definition requirements for the 34 ton (payload) flatbed semitrailer (stlr), designated by the Army (TACOM) as the M872A4. This tactical stlr is for use on paved and secondary roads (gravel and dirt). The trail/off-road usage is estimated at 5% of its total lifetime mileage.

1.2 Type of PD. This vehicle PD contains both the performance requirements and definition requirements for the M872A4. The vehicle performance requirements shall have priority over definition requirements in the event of any conflict. The M872A4 stlr will transport two M113 Family of Vehicles (FOV) variants, one 40’ or two 20’ ISO containers, equivalent in breakbulk cargo, including palletized cargo, such as ammunition.

1.3 Colors. Available vehicle top coat colors are as follows: forest green chip 34094 and brown chip

33446. Note: all part support from Government Supply System will be furnished with top coat of paint that is green color chip 34094. The procuring agency will specify the vehicle top coat color for each production vehicle.

1.4 Kits. The procuring activity shall specify which of the following kits are to be furnished with each production vehicle:

a. Side Rack Kit with Side Racks in CARC brown chip 33446 top coat paint color.

b. Side Rack Kit with Side Racks in CARC forest green chip 34094 top coat paint color.

c. Tarpaulin Kit in CARC, brown chip 33446 color.

d. Tarpaulin Kit in CARC, forest green chip 34094 color.

1.5 Prime Movers. The designated prime mover tractors for the M872A4 are the M915, M915A1, M915A2, M915A3, and M915A4. The M878A2 yard tractor is designated for moving the M872A4 in a port area, maintenance yard or on and off RO/RO ships.

1.6 Commercial Components. The prime contractor is allowed to use off-the-shelf commercial components/material providing the performance (DOT and Army) and definition requirements specified herein are met, along with the paint/finish requirements specified herein.

1.7 Order of Precedence. In the event of conflict between the text of this specification, and the references cited herein; the text of this PD specification takes precedence.

1.8 Definitions.

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ATPD 2332F

1.8.1 Trail. One lane, dry weather, unimproved, seldom maintained, loose surface road that are intended for low density traffic. Trails have a minimum lane width of eight feet, with no large obstacles (boulders, logs, and /or stumps). The trail test course is to have an average Root Mean Square (RMS) value of ―1.0‖.

1.8.2 Transportability. The lifting and tiedown requirements in MIL-STD-209 are necessary to permit compatibility between military equipment, stlrs, and the transportation systems used for deployments. Also, included in this 209 standard are dimensional limits, design considerations, positioning requirements, and strength requirements for lifting provisions, to include helicopter External Air Transport (EAT) and vehicle tie down provisions. The basic transportability criteria for the use in development and shipment of items of materiel shall be in accordance with MIL-STD-1366. This standard covers dimensional and weight limitations for all modes of transport to meet the interface requirements of the Defense Transportation System (DTS), highways, tunnels, bridges, railways, etc.. The DTS assets include, rotary and fixed wing aircraft, railcars, ships, barges, etc. for worldwide transport and deployment.

2. APPLICABLE DOCUMENTS

2.1 Government Documents.

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the applicable issue of these documents are those listed in the published issue of the Department of Defense Index of Specifications and Standards (DODISS) on the date the solicitation is published. (see 6.2).

SPECIFICATIONS

FEDERAL

MMM-A-181 Adhesives, Phenol, Resorcinol or Melamine Base TT-C-490 Cleaning Method for Ferrous Surfaces and Pretreatment for Organic Coatings

DEPARTMENT OF DEFENSE

MIL-PRF-20696 Cloth, Waterproof, Weather Resistant MIL-R-24049 Rope, Polypropylene MIL-DTL-53022 Primer, Epoxy Coating, Corrosion Inhibiting, Lead & Chromate Free MIL-DTL-53030 Primer Coating, Epoxy, Water Reducible, Lead & Chromate Free MIL-DTL-53039 Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant MIL-DTL-53084 Primer, Cathodic Electrodeposition, Chemical Agent Resistant

STANDARDS

FEDERAL

FED-STD-595/33446 Brown FED-STD-595/34094 Forest Green

DEPARTMENT OF DEFENSE

MIL-STD-209 Interface Standard for Lifting & Tiedown Provisions MIL-STD-642 Identification Markings of Combat & Tactical Transport Vehicles MIL-HDBK-759 Human Factors Engineering Design for Army Material MIL-STD-810 Environmental Tests Methods & Engineering Guidelines MIL-STD-889 Dissimilar Metals MIL-STD-1366 Interface Standard for Transportability Criteria

MIL-STD-1472 Human Engineering AR 70-38 Research, Development, Test & Evaluation of Material for

Extreme Climatic Conditions

2.1.2 Other applicable Government Documents, drawings, and publications.

2.1.3 DEPARTMENT OF DEFENSE

Department of Defense Index of Specifications and Standards (DODISS).

(Copies of the DODISS are available on a yearly subscription basis either from the Government Print Office for hard copy, or microfiche copies are available from the Director, Navy Publication and Printing Service Office, 700 Robbins Avenue, Philadelphia, PA 19111-5093.)

DEPARTMENT OF TRANSPORTATION (DOT)

CFR 393.40 Required Brake Systems CFR 393.41 Parking Brake System CFR 393.42 Brakes Required on all Wheels CFR 393.43 Breakaway and Emergency Braking CFR 393.45 Brake Tubing and Hose Adequacy CFR 393.46 Brake Tubing and Hose Connections CFR 393.47 Brake Lining CFR 393.52 Brake Performance CFR 393.70 Coupling Devices and Towing CFR 393.86 Rear End Protection CFR 393.100 Protection against Shifting or Falling Cargo CFR 393.106 Front-end Structure

Title 49, Part 393, Parts and Accessories necessary for Safe Operation 49, CFR 393.201 Frames 49, CFR 393.205 Wheels 49, CFR 393.207 Suspension Systems

Title 49, Part 571, Federal Motor Vehicle Safety Standards 49, CFR571.106 Brake Hoses… 49, CFR571.108 Lamps, Reflective Devices… 49, CFR571.120 Tire Selection and Rims 49, CFR571.121 Air Brake Systems 49, CFR571.223 Rear Impact Guard 49, CFR571.224 Rear Impact Protection

(Application for copies of DOT publications should reference the Code of Federal Regulations, 49 CFR, and the Federal Register, and should be addressed to the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.)

2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DOD adopted are those listed in the issue of the DOISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation (see 6.2).

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 Weld Symbols AWS A3.0 Weld Term & Definitions AWS B2.1 Specification for Welding Procedure & Performance Qualifications

AWS D1.1 Structural Welding Code – Steel AWS D1.2 Structural Welding Code – Aluminum

(Application for copies of AWS publications should be addressed to the American Welding Society, 2501

NW 7th Street, Miami, Fl. 31025, or at www.aws.org).

THE TIRE AND RIM ASSOCIATION, INC. Year Book.

(Application for copies of Tire and Rim Association publications should be addressed to The Tire and Rim Association, Inc., 175 Montrose West Ave., Copley, Ohio 44321, or at www.us-tra.org/).

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 668 Series I Freight Containers - - - Classification, Dimensions & Ratings.

ISO 1161 Series I Freight Containers - - - Corner Fittings - - - Specification.

(Application for copies of ISO publications should be addressed to Global Engineering Documents, 7730 Caronelet, Suite 407, St. Louis, Mo. 63105, or at www.iso.org/).

NATO STANDARDIZATION AGREEMENT (STANAG)

STANAG 2601 Standardization of Voltage of Electrical System in Tactical Vehicles STANAG 2604 Braking System between Tractors and Semitrailers STANAG 4007 Electrical Connectors between Tractors and Trailers STANAG 4009 Fifth Wheel Attachments and NATO Kingpin STANAG 4381 Blackout Lighting Systems for Tactical Landing Vehicles AMovP-01 Regulations and Procedures for Road Movements & Identification of

Movement and Traffic Control Personnel and Agencies (Supersedes

STANAG 2154)

(Obtain copies from Standardization Documents Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, Pa. 19111-5094, or at dami_standardization@conus.army.mil) .

Society of Automotive Engineers Incorporated (SAE, INC)

SAE Standards and Recommended Practices J318 Air Brake Gladhand Service (Control) and Emergency (Supply) Line

Couplers – Trucks, Truck-Tractors, and Trailers (DoD adopted) J387 ® Terminology – Motor Vehicle Lighting J534 Lubrication Fittings J560 ® Seven-Conductor Electrical Connector for Truck-Trailer J588 Jumper Cable. Turn signal lamps for use on Motor vehicles less than

2032 MM in overall width.

J682 Rear Wheel splash and Stone Throw protection J700 Upper Coupler Kingpin – Commercial Trailers and Semitrailers J702 Brake and Electrical Connection Locations – Truck Tractor and Truck

Trailer J1292 Automobile, Truck, Truck-Tractor, Trailer and Motor Coach Wiring J1889 L.E.D. Signal and Marking Lighting Devices J2394 Seven Conductor Cable for ABS Power—Truck and Bus http://www.aws.org/ http://www.us-tra.org/ http://www.iso.org/ mailto:dami_standardization@conus.army.mil

(Application for copies of SAE publications can be found at SAE, Inc., 400 Commonwealth Drive, Warrendale, Pa. 15096, or at www.sae.org).

(Non-Government Standards and other publications are normally available from the organizations that prepare or distribute the documents. These documents also may be available through the librarian or other informational services.)

3. REQUIREMENTS

3.1 First Article Tests. When specified (see 6.2), the contractor shall furnish stlrs that shall be subjected to first article inspection IAW 4.1.1.

3.2 General Design. The subject army stlr is considered a tactical rear area support vehicle due to its mission profile, including some off road travel, under extreme climatic conditions, etc. Subject stlr will have Government parts support and a Department of Army (DA) technical manual. All performance and definition requirements here in this PD are concurrent requirements unless nature prevents it from happening; such as fording in water when the ambient temperature is below 32 degrees F, during middle of Winter. Design will be such that maintenance and servicing can be accomplished without introducing new special tools in the Army supply system.

The stlr shall be a 34 (off road payload rating) ton flatbed dual purpose stlr. The stlr, components, assemblies, and accessories shall conform to all FMVSS applicable on the date of published solicitation.

3.2.1 Accessibility. The design of the vehicle and optional equipment shall permit access for routine servicing and shall permit access for replacement and adjustment of component parts and accessories while personnel are wearing the MOPP IV gear and arctic gear.

3.2.2 Federal Motor Vehicle Safety Standards (FMVSS). Subject vehicle shall comply with all Federal

Motor Vehicle Safety Standards less license plate area and ABS warning light location

3.2.3 Side Slopes. The loaded stlr when towed by truck–tractor shall be capable of operating satisfactory on a 10 % side slope, at reduced speed.

3.2.4 Longitudinal Slopes. The loaded stlr when towed by truck-tractor shall be capable of operating satisfactorily on a 20% longitudinal slope.

3.3 Performance. The stlr shall evidence no part failure, deformation, permanent set, or interference between parts, as applicable, when towed, both empty and when loaded with rated payload to include R/M testing:

(a) At speeds; 46 - 65 mph over paved roads *

(b) At speeds; 20 - 45 mph over secondary roads (gravel & dirt) roads *

(c) At speeds; 02 -10 mph on trails/off-road. *

* Weather and terrain conditions, etc. permitting

3.3.1 Turning Ability. The stlr shall be capable of a 90 degree turn angle in both directions to the coupled towing vehicle (M915 family truck) without cramping, side-slipping, or damage to the stlr or the towing vehicle.

3.3.2 Tracking Ability. The stlr shall conform to the tracking requirements of 49CFR393.70(a) when the axles are aligned and the stlr shall track in a straight line within 2 inches.

3.3.3 Payload and Payload Distribution. The rated payload of the stlr, is 34 tons (68,000 pounds). It shall be capable of transporting a single American National Standards Institute/International Organization for Standardization (ANSI/ISO) standard size 40 foot long container, two M113s, or one or two 20 foot long ANSI/ISO containers. Regardless of the load composition, the stlr shall be capable of transporting loads with a combined weight of 68,000 pounds of breakbulk cargo such as ammunition. The load shall be distributed over the load space.

See Table I. In addition, the stlr shall be able to transport breakbulk cargo not uniformly distributed over the platform load space, this requirement includes 34 tons over 20 feet length of platform space.

http://www.sae.org/

TABLE I: PAYLOAD DISTRIBUTION

Quantity Type of Load Maximum Weight (pounds) N/A

40 foot ISO container 20 foot ISO containers 20 foot ISO container in center M113 Breakbulk

67,200 67,200 53,000 only if less than 34 ton 68,000

3.3.3.1 Tracked Vehicle Payload. The stlr shall be capable of transporting two M113s, or any two vehicles using the M113 chassis. The M113’s weight shall be distributed over an area 12‖ X 115‖ inches (in), along the left and right edges of the platform. The tracked vehicles shall be placed on the stlr for optimum weight distribution.

3.3.3.2 M915 Fifth Wheel Capacity. When coupled to the M915, the semitrailer at gross vehicle weight shall not exceed the vertical load capacity, 30,000 lbs, of the fifth wheel.

3.4 Life Cycle Operations. The reliability and maintainability requirements shall be demonstrated during the stlr operations for a total of 6,000 miles per vehicle IAW Table II. The payload and environmental requirements are listed below.

TABLE II: OPERATIONAL PROFILE

COURSE Mileage, Percent %

Loading Condition Maximum Speed, Miles Per hour (mph)

10% Side Slope, 20% Longitudinal Slope

Primary Road 65

At rated Payload Empty

45-65 45-65

At Rated Payload

Improved Secondary Road (Gravel/Dirt)

At rated payload Empty

30-45 30-45

At Rated Payload

Off Road 5 At Rated Payload 5-10 At Rated payload Fording (20 Inches) 0 At rated payload 0-2

10% Side Slope, 30% up & down grade

0 At rated payload 3-5 At Rated Payload

3.4.1 Reliability (R). The reliability of the stlr shall be 6,000 Mean Miles Between Hardware Mission Failures (MMBHMF). For calculation of MMBHMF, a failure is anything that prevents the stlr from operating, reduces performance below essential levels, indicates that further operation would be unsafe, or indicates that further operation might result in extensive damage to the equipment. Any of these conditions that cannot be corrected by the crew in one hour using the Basic Issue Items (BII) that are carried on the prime mover or the stlr shall be considered a failure. Maintenance and human induced failures are excluded.

3.4.2 Maintainability (M). The total maintenance time, exclusive of daily crew checks and services shall not exceed 8 man hours during 6,000 miles of specified operation over the OMS/MF. This is a maintenance ratio (MR) of 0.04 at 30 miles of operation, equivalent to one hour of operation. The scheduled maintenance interval is one year, except for maintenance interval on the wheel ends which is to be three years. Maintenance and human induced failures are excluded.

3.4.3 Environmental. The stlr, and components, shall be able to withstand and operate under the following extreme conditions of weather, terrain and roads specified herein:

a. Ambient Air Temperatures: At minus (-) 40 degrees Fahrenheit (F) to plus (+) 130 degrees Fahrenheit

IAW MIL-STD-810.

b. Solar Radiation: Maximum intensity.

c. Rain: Any amount, with reduced braking.

d. Dust/Sand: Any amount in the air.

e. Fording: It shall be able to ford water up to 20 inches deep without water contamination of hubs/wheel bearings.

f. Storage: It shall withstand storage from -40 to 160 degrees Fahrenheit without deterioration.

g. Wind: Up to 33 MPH steady and 45 MPH gusting.

h. Relative Humidity: 0-100%.

i. Atmospheric Pressure, Hail, Altitude… N/A

3.4.3.1 Ozone. All rubber components used on the stlr shall be ozone resistant to the degree specified

IAW ASTM D1171 using ozone chamber exposure Method A.

3.4.3.2 Fungus. The stlr shall be able to operate in any environment that encourages growth of fungus, mildew, etc., for a minimum of 30 days, using test method 508.5 of MIL-STD-810.

3.5 Dissimilar Metals. All dissimilar metals, as defined in MIL-STD 889, used throughout the vehicle shall be insulated (ex. by use of primer and paint, etc.) from one another to prevent galvanic action.

3.6 Materials. Material used in the manufacture of the vehicle shall be new and of the highest commercial quality as normally used for this type of equipment, considering strength, durability, ductility, and the purpose for which the equipment is to be used.

3.6.1 Prohibited Materials. Asbestos, cadmium, and radioactive materials shall not be used.

3.6.2 Recycled, Virgin and Reclaimed Materials. Two rubber chock blocks with zinc plated eye bolt on block end area surface.

3.7 Reserved.

3.8 Vehicle Dimension Requirements. The stlr, uncoupled from the towing vehicle, resting level on the landing legs, without payload, on level ground, shall conform to the dimensions specified in Table llI.

TABLE Ill: Vehicle Dimension Requirements

Overall length 45 feet. Not to exceed Overall width 96 inches Length of ISO/Breakbulk load space 40 feet Maximum Platform height 59 inches at curb weight Reserved

Distance from front of M872A4 to vertical centerline of kingpin.

32 inches (max)

Upper fifth wheel height (empty) from the ground to underside of upper 5th wheel plate.

51+/- 1 inches empty

Landing gear swing clearance (radius from centerline of kingpin to any portion of stlr 6 inches or more below upper fifth wheel plate)

96 inches (minimum)

M872A4 Fording height (1/4 hour) 20 inches minimum Height with installed bulkhead and installed side racks

As determined by features

3.8.1 Vehicle Curb Weight Requirements.

a. Subject vehicle design goal for curb weight (including BII items) shall not exceed 18,800 pounds maximum.

b. State of the Art creative means shall be used to keep subject stlr curb weight at a minimum.

An example of this is having ellipse holes in the web of the main beam.

c. Weights of Kits to include (Tiedown chains and Load turn binder’s, etc.) procured concurrently with the vehicle shall have their weights be considered as part of the payload.

d. Tiedown chains and Load binders placed on the vehicle by the field/test site shall not be considered part of the vehicle initial curb weight.

e. Contractor shall perform a weight study on all components for stlr in order to achieve state of the art curb weight.

3.9 Construction. The two main longitudinal frame members shall be fabricated of high strength steel with a yield strength of not less than 100,000 pounds per square inch (psi). The yield strength of main frame cross-members shall be rated at not less than 70,000 psi minimum.

3.9.1 Frame. The frame shall not have any performance failures on components IAW 49CFR393.201. The main frame members shall be adequately braced with a sufficient number of cross members to prevent permanent deformation. The outside frame members shall run the full length of the load space. The rear cross member shall extend the full width of the stlr. With the stlr statically loaded and the load distributed as specified herein, the maximum fiber stress in any frame member shall be no greater than one third of the material yield strength. Weight reduction techniques may be used (holes in web of main beams) as long as performance requirements are maintained (example, Super Beam). The frame shall show no permanent deformation after torsional loads from off road operations.

3.9.1.1 Frame Flanges. Main frame members shall have one piece upper and lower flanges, running the length of the stlr.

3.9.1.2 Frame Splices. The frame members shall not be spliced.

3.10 Axles and Suspension. Axles shall have the manufacturers rated capacity at least 25,000 pounds.

Suspension clearances shall preclude interference between tires and any portion of the stlr when operating under all off road conditions, specified herein. The stlr shall be of tri-axle configuration, using axles and a suspension currently being produced for the commercial field. The suspension shall have the manufacturer’s rating capacity at least 75,000 pounds.

3.10.1 Tri-axle Assembly. The tri-axle assembly on stlr shall be positioned and individual axles spaced so

65.2% is the design goal and has a +3% tolerance of the stlr gross weight (curb weight plus payload) will be supported by the tri-axle assembly, with the stlr loaded as specified herein. The hubodometer shall be installed on road side forward most wheel axle.

3.10.2 Suspension System. The suspension system shall be IAW 49CFR393.207. Each component of the suspension system shall have a rated capacity at least equal to the load imposed by loading conditions outlined in Table 1. Clearances shall prevent interference between the tires and any other parts of the stlr under the operating conditions specified herein, except that minor tire scuffing on frame members is allowed during ramp negotiations for roll-on roll-off ship requirements. Equal loading shall be maintained between axles within 10%. Adequate articulation shall be provided to accommodate a 15 degree ramp angle with the M878A2 yard tractor. Bushings shall be of extended long-life nylon or equivalent material.

3.10.2.1 Suspension Articulation. Sufficient wheel articulation shall be provided to maintain equal loading on each axle within 10% under normal operating conditions as specified herein. The jounce bumpers shall keep the axles from hitting the frame.

a. With first and third wheels on one side and center wheel on opposite side, elevated four inches above remaining wheels.

b. With any pair of opposite wheels elevated four inches above remaining wheels.

c With any two pairs of opposite wheels elevated four inches above the remaining pair.

3.10.2.2 Lubrication. Grease lubrication fittings shall conform to SAE J534. The hub cap, bearings, and hub shall be filled with military lubricant, MIL-PRF-10924.

3.11 Axle and Wheel Ends.

a Axles and brakes shall be commercially rated as 25,000 pounds capacity.

b Brakes shall be air brakes of S-cam drum type.

c ABS required on all axles. ABS diagnostic box shall be located above fording level with easy access for maintenance.

d ABS Diagnostic light is to be mounted on front of stlr on an angle with visibility to driver without glare.

e Spring failsafe brakes are required on all axle ends.

f Deleted g Deleted h The vehicle brake system shall meet 49CFR393, applicable requirements. In addition, glad hands shall be self-sealing type when truck air hoses are disconnected.

i Brake shoes shall be provided of extended life type.

j The DTC Jennerstown brake fade test or equal shall be performed on one (1) PVT vehicle, with full payload.

k Pre set wheel ends shall be provided, which will utilize pre-adjusted bearings, improved seals, and bearing life and reduce maintenance. That is, pre-set wheel ends shall utilize pre-adjusted bearings, be of field service design, and utilize extended life wheel seals.

l Wheel end grease will be MIL-PRF-10924 m Wheel ends, hubs, etc. shall be filled with MIL-PRF-10924 grease n The hub caps shall be furnished of non-window type and have fill opening in the cap.

o Provide single wheel mounting lug nut, galvanized for each wheel stud. Provide single wheel/axle end galvanized pro torque type mounting nut, for each axle end.

p STEMCO hubodometer shall be provided on road-side, front axle,calibrated in miles.

q Backing plate to the axle end is not required.

s Caging bolts shall be provided in plastic bag and stored in BII box with galvanized pipe plugs or standard rubber cap plugs installed in the failsafe brake chamber in place of the caging bolts.

t All failsafe brake chamber assemblies to either vent to axle tube or assembly to be sealed.

u S-Cam assembly to have bushings which are open ended to the atmosphere on one side and completely sealed on the opposite side.

3.11.1 Wheels and Tires. The Wheels shall be IAW 49CFR393.205 and meet the performance requirements in FMVSS 120. The stlr shall have dual disc type wheels on each axle, 8.25 x 22.5. The rims shall conform to Tire and Rim Association recommendations for the type and size of tires furnished. Tires and rims shall be the same size for all wheels on the stlr.

a. Tires. Tires shall be steel belted radial tubeless type. Tires shall be of a published rated capacity at least equal to load imposed on each tire with stlr fully payloaded and evenly distributed. Tires and tire ratings shall conform to Tire and Rim Association recommendations. The stlr shall be furnished with Michelin tires, size XZE 11R22.5, load range H. Tire air pressure to be 95 psi, and shall be stenciled on both sides of the stlr. Tires shall have a minimum wear out life of at least 8,000 miles. Tires shall be compounded for off road usage as the same for the truck. Tires furnished shall have a storage life of 4 years.

b. Tire Changing Tools. The axle jack, lug nut wrench, and two piece breaker bar shall be furnished as part of the BII. Valve caps shall be furnished for all wheel assemblies. Brass inner tire valve extensions shall be furnished.

c. Wheel Requirements. The wheels furnished shall be hub piloted drum type. Wheels shall have all surfaces cleaned, treated, and painted with CARC paint over zinc rich primer prior to mounting the tire on to the wheel. The inner and outer wheels shall be mounted with wide flanged wheel phosphate coated and CARC painted lug nuts, one per stud. Torque wheel lug nuts with use of a torque wrench in proper commercial sequence.

d. Spare Wheel and Tire Assembly. The stlr shall have an inflated spare tire mounted on a spare wheel or rim, installed in a carrier. The spare tire shall be of the same size, tread design and load range (ply rating) as the tires on the stlr.

e. Spare Tire Carrier. A spare-tire winch, with stainless steel cable, style carrier shall be installed under the stlr, on the curbside, in an accessible location. A commercial pad lock, brass, keyed alike to the tool and tarp boxes, 2 ½‖ to 2‖ shackle, with key shall be provided for securing the tire within the carrier to prevent pilferage and accidental loss. Threaded fasteners, when used to secure the spare tire in the carrier, shall be zinc-plated. The carrier shall enable the safe removal of the tire from the carrier and return from the ground without personnel positioning part of their body under the spare tire assembly.

3.12 Brakes. The brakes shall meet the performance requirements of 49CFR393, as applicable.

3.12.1 Service Brakes. The service brakes shall be of the full air internal expanding type and shall conform to 49CFR393, as applicable. The braking system shall be installed so as to have protection against damage caused by objects striking components, and meet the requirements of FMVSS121. The braking system shall include:

(a) Automatic slack adjusters IAW 49CFR393.53

(b) Plastic tubing lines

(c) Hose connections IAW FMVSS106 and SAE J702

(d) All other components required for a complete-air-brake system.

(e) Burnish brakes per commercial standards on vehicles going to test (PVT).

(f) Extended life linings without metal content

(g) Air lines shall be secured to prevent rubbing and hanging down. All holes that air lines and electrical harnesses go through shall have grommets

(h) That slack adjuster and air chambers shall be mounted above the bottom of the axle tube.

(i) Brake chambers relay emergency valve

(j) Air reservoirs to have remote operating drain valve control positioned on the road side of the vehicle platform.

(k) No brake backing plate is to be furnished.

3.12.1.2 Service Brake Performance. The stlr service brakes with the use of the truck tractor-stlr combination, with rated payload, shall meet the stopping distance requirements of 49CFR393.52.

3.12.2 Glad Hands. The glad hands shall conform to SAE J318. Glad hand location shall comply with SAE J702 self-sealing type.

3.12.3 Parking brakes. The parking brakes shall be IAW 49CFR393.41 and 49CFR 571.121. The spring parking brakes shall be on each axle and shall automatically apply upon disconnection of the emergency air lines and under emergency conditions. The parking brakes shall hold the fully loaded stlr on a 20% longitudinal grade facing both uphill and downhill.

3.12.4 Anti-Lock Brake System (ABS). The trailer shall be equipped with a 4S/2M ABS and shall meet current industry and CFR49.571.121 requirements. The ABS shall operate when 12v power is supplied, as well as when 24v power is supplied separately. Use of a voltage converter box to meet the 24v operation requirement is acceptable. The ABS Electronic Control Unit (ECU) shall include wiring provisions to transmit the stlr (cable, SAE J2394) ABS malfunction signal to the prime mover cab. ABS systems that are used on PLC (Power Line Carrier) communication technology to transmit ABS malfunction shall be provided. The blink light operation shall be in view of truck operator. The ABS diagnostic box shall be water proof to road splash/spray. The diagnostic warning light shall be mounted on an angle at the left side front of the stlr.

3.13 Upper fifth wheel plate. The upper fifth wheel plate shall be designed for completely covering, and for use with, either a full oscillating or fore and aft rocking fifth wheel. It shall be bolted in place with Huck bolts or an equivalent fastening system that provides comparable characteristics for maintaining torque and the necessary strength properties. All blind cavities in the mounting frame area shall have 1‖ drain holes for water removal. The upper fifth wheel plate shall conform to CFR393.70(b). The bottom surface of upper fifth wheel plate to be coated with 15W or 30W oil. The forward end of the upper fifth wheel plate shall have a turned up lip for ease of coupling.

The lip shall provide for a smooth interface with the M915A3/A4 5th wheel top plate urethane inserts. The lip may have cutouts for electrical and brake air provisions.

3.13.1 Kingpin. The kingpin shall be 2‖, of heat treated alloy steel at 380-420 BHN, and shall conform to

SAE J700. Installed kingpins shall meet or exceed the performance requirements of the American Association of Railroads (AAR) standard M-931, and the Truck and Trailer Manufacturer’s Association (TTMA). The material shall be AISI 4320H or 4718H, Spool Style, and have strength of 190,000 P.S.I. ultimate strength, and 145,000 p.s.i.

yield strength.

3.14 Landing Gear (LG). The minimum requirements are listed in below paragraphs a through z. Those features and performance not defined in the below paragraphs are to be the contractor’s commercial design.

a. Exceed all AAR M-931 and all TTMA RP-4 performance specifications.

b. Shall have a upper housing and retract tube of material that has minimum yield of 80,000 pounds.

c. Shall meet the Industry standard TTMA mounting plate.

d. Shall have a side load capacity of 29,000 pounds.

e. Shall have a static vertical load capacity of a minimum of 170,000 pounds .

f. Shall have a minimum of 60,000 pounds lifting capacity at 100 foot-pounds input torque.

g. The gear box high ratio to be 4.5 turns per inch of travel.

h. The gear box low ratio to be 34.5 turns per inch of travel.

i. A sealed system (gear box) specially designed to shift easily even in sub zero temperature.

j. Shaft seals added to all driveshaft and crankshaft bushings.

k. The grease tube completely surrounds the elevating screw.

l. Self-lubricating powdered metal shaft bushings for increased service life.

m. The landing gear shall include double-d crank handle connection and brace attachments.

n. The landing gear hardware installation to stlr shall be rated for 15% side slope and 20% longitudinal slope (up and down).

o. The landing gear shall have a minimum 5 year warranty.

p. The landing gear shall use premium grade lube (rated for –60 degree F to 225 degree F).

q. The landing gear shall be located to allow coupling to truck-tractors with fifth wheel height ranging from 50‖ to 56‖ (empty).

r. In addition, two (2) soft sand/soft mud ground boards shall be provided for landing gear feet. This item shall have a galvanized-painted handle. Also these two boards shall be fabricated with Apitong hardwood (TTMA load rating per 3.18.1.1) and small diameter spiral galvanized nails. Stowage provisions for these two Apitong soft terrain boards shall be in the BII box, when not in use.

s. The landing leg handle shall be located on the curbside of the semitrailer.

t. Stowage provisions to be provided for the landing gear box handle that will hold the handle in place during off road operations.

u. The landing gear to be braced to frame in both lateral directions and in fore and aft direction for slopes and wind conditions specified herein.

v. deleted

w. The gear box to be commercial ―no lube‖ type.

x. The LG shall be painted per requirements herein for ferrous material.

y. The removable cushion foot shall be installed which absorbs 50 percent more shock than conventional footwear, also, the cushion foot can be removed with a single bolt.

z. A wrap around upper leg cover to prevent water infiltration.

3.15 Lighting. The performance lighting test shall be IAW FMVSS-108.

3.15.1 Lighting. All running lights and reflectors with the exception of the rear side marker lights shall be mounted in recessed or otherwise guarded locations, for protection. The electrical end connections shall be greased to current commercial standards. The brake lights shall override the four-way emergency flashers or the two systems shall be independent of each other. Lights and reflectors shall not be mounted on vertical surfaces of the rube rail. Turn signal lamps shall conform to SAE J588. All electrical wiring shall conform to SAE J1292. The rear identification lights are to be located in a protected location. Grounding screws shall be to commercial standards for extended life without maintenance.

3.15.2 Running Light Requirements. All vehicle running lights except blackout running lights requirements shall be of the commercial U.S. 12/24 volt (V) LED type that fully meets the DOT/FMVSS requirements when 12 or 24 volts D.C operate the running lights. License plate light and related harness is not to be furnished. Blackout LED running lights (tail, turn, stop) lights are to be set up for 24 volt only IAW STANAG 4381. Midship turn signals are not to be furnished. Conspicuity markings using reflective sheeting tape with extended life shall be furnished. Commercial aluminum frame reflectors (painted before assembly) are to be used.

All electrical wiring is to conform to SAE J1292.

3.15.2.1 Blackout Lighting System. A blackout 24 volt LED vehicle running light system for tail light, stop light, and turn signals (per STANAG 4381) shall be provided (ref. 12258212/19207 dwg, 24 volt). The energy emission of any vehicle light source to be illuminated in blackout mode shall be limited to the visible spectrum of 380 to 700 nanometers (nm), with the following exception: energy may be radiated in the 700 to 1200 nm band range provided it is less that 1% of the energy radiated in the 380 to 700 nm band. The 24 volt lamp assembly is to include one, yellow, solid state lamp in the center and a pair of red, solid state lamps on each side of the center lamp.

The four red lamps will appear as individual lights up to 60 feet, from 60 to 120 feet the four red lights will converge into two points of light. Lights will be visible at 1000, plus or minus 200 feet. When vehicle is on a 20 percent downgrade no light is to be visible from an altitude which exceeds 400 feet.

3.15.3 LED. The LED’s shall be IAW SAE J1889 and related electrical harness wires are to be of commercial design (ref. Peterson); currently being produced and marketed by the supplier, and fully meet the LED light requirements described herein for one LED running light system, operational with either 12 or 24 volt.

3.15.3.1 Electrical Harness Requirements. All electrical harness connections are to be water tight, environmentally sealed, positive retention type to protect it from rain, road spray, etc. The frame mating surfaces between LED lights, and related harnesses, clamps shall be cleaned, treated, primed and painted prior to installation of electrical components. All LED lights, reflectors and electrical wiring shall be mounted in recessed or otherwise protected locations. Wiring shall be secured to prevent chaffing and loose connections.

3.15.4 Electrical Receptacle. The 7 pin, 12 volt commercial electrical receptacle (per SAE J560) with spring cover and 12 pin, 24-volt electrical power inlet receptacle (P/N MS75021-1) are to be furnished and be interconnected right after these two receptacles without the use of circuit breakers. Both receptacles are to be located as required by SAE J702.

3.15.4.1 Receptacles. The stlr shall be equipped with one 12-contact receptacle with cover, and one 7-contact receptacle with cover installed at the front of the stlr. The 12-contact receptacle shall conform to MS75021-1 and be equipped with a cover assembly conforming to drawing 7731428, nut grommet, retainer conforming to drawing 7723309, and grommet, electrical connector conforming to drawing 7722333. The 7-contact receptacle shall conform to SAE J560 round socket for an intermediate connector cable. Interconnections between the 12-contact and 7-contact receptacles shall be as per Table lV below:

Table lV: 24V CONNECTOR PIN ASSIGNMENTS

PIN USE

A 24V left blackout tail B Circuit 3 (8V-30V) C 24V right blackout tail D Circuit 1 ground

E Circuits 2 and 6 (8V-30V service) F 24V blackout stop H Not used J Circuit 5 (8V-30V right turn) K Not used L Circuit 1 ground M Not used N Not used

Circuits B and J on tactical tractors, are combination stop and turn signal indicator circuits. The normal 12 V turn signal lights will function both as turn signals and stop lights and the normal 12 V stop lights will not be in operation when the stlr is connected to a towing vehicle with a 24 V power supply. Because of this condition, the number 4 stop light circuit is not connected to the 24 V, 12 contact receptacle.

3.16 Rear End Protection. The rear end protection shall comply with the requirements of 49CFR571.223 and 49CFR571.224. In addition, furnish two rubber dock bumpers that shall extend between 2.0 and 4.5 inches beyond the rear of stlr. The rubber dock bumper shall be attached IAW commercial standards.

3.17 Mud Flaps. Anti-Sail mud flaps shall be provided behind the rear wheels IAW SAE J682 and installed IAW commercial standards.

3.18 Platform. The platform shall have a flat front (when the bulkhead is removed) and stainless steel stake pockets that are located sufficiently outboard to provide a minimum of 90’’ load space width inside the racks for the entire length of the load surface. If protruding type pockets are provided, they shall be protected all around by a stainless steel rub rail 2 inches wide and 5/16‖ thick. The stlr deck shall present no restrictions on the sides or end to the opening and closing of the doors of mounted containers or to access by forklifts to tine pockets in pallets and TRICON’s located on the stlr deck.

3.18.1 Decking. The requirements are for open areas of the stlr platform to have full length, non-pressure treated, dense Apitong/Keruing hardwood planks, 1 3/8 inch thick with vertical finger joints and be of non-ship-lap type. Finger joints are to be bonded together using adhesive MMM-A-181. Finger joints are to be a minimum of 60 inches apart. The deck boards are to be attached to each frame cross member with two plated counter-sunk self threading screws. The ends of each full length deck board shall be supported by frame structure.

The floor deck boards is to be 3/8‖ above top deck/platform metal surfaces.

3.18.1.1 Test Performance Requirements. Each floor board shall be certified to have been successfully proof loaded, exceeding Truck Trailer Manufacturers Association (TTMA) load rating criteria by continuously moving each board lengthwise through a mechanism exerting a constant test load along the board’s entire length.

This mechanism shall reject any plank, which does not meet the TTMA load rating criteria. The finger joints shall withstand a minimum bending strength of 13,300 psi.

3.18.1.2 Attachment of Flooring. Flooring shall be secured with countersunk zinc plated self tapping screws. Phosphate coated screws are permitted. Not less than two securing screws shall be installed at each cross sill/member. The top of each countersunk screw shall not be less than 1/8‖ below the top of the wood surface.

3.18.2 Stake Pockets. Stainless steel stake pockets shall be furnished at 48‖ on center on all stlrs. Stake pockets shall be protected, on all three sides of the platform by stainless steel rub rails not less than 2 inches wide and not less than 0.31inch thick. The stakes and side racks shall not come loose during rough terrain travel. Stake pockets shall have welded in supports for holding wood deck boards in place that end (in part) next to the welded in stake pocket. Stake pockets shall be painted after assembly with commercial primer, epoxy primer, and finish CARC top coat.

3.18.3 Front Bulkhead. Each stlr shall be equipped with a wraparound, bolt-on bulkhead. Sheet metal used in the construction of the bulkhead shall be 5052-H32 aluminum alloy, and all other components shall be manufactured from 6061-T6 aluminum extrusion. Inside stowage of front bulkhead with space for side racks, and bows. It shall be a removable type that meets 49CFR393.106 (d) (1) standards, and includes handles to allow lift off by personnel. Provision shall be provided on the structure for fork truck removal, replacement, etc. The height shall be compatible with installation of the side rack kit with V-front construction (Ref. Aero Industries Inc). The front bulkhead shall be treated, primed and painted on all surfaces. The inside of the front bulkhead stowage space shall be tuff coated or equivalent (3/16 inch thick min.).

3.19 Side Rack Panel Kit. This kit consists of all the panels required for one stlr. This includes the features to retain panel assemblies on place during rough terrain travel. The stlr shall be furnished with side rack kits when specified by the procurement activity. The side panel on the stlr shall be stowed at the front bulkhead.

The panels shall be secured during off road operations, when stowed.

a. Height – 4 feet.

b. Panel material – 6061-T6, extruded aluminum at .125‖ thick or the Fiber Reinforced Panels (FRP), 5/8‖ thick with exterior plywood or Fiber-Lite Side-Kit exterior plywood panel assembly. The fiberglass exterior shall be on both sides. The color shall be green chip 34094 or brown chip 33446. All exposed (edges) shall be sealed. The fiber-lite-side-kit panels with FRP on both sides of plywood also available with an aluminum metal wrap. Two hand/forklift holes shall be provided in each FRP panel. Exposed edges created by drilling the hand holes shall be sealed and the top edge of the holes shall be reinforced with an aluminum plate. All following requirements shall be as an option to the aluminum panel call out, as applicable.

c. All sides of panels, stakes, panel top rail to be painted with commercial wash primer, epoxy primer and then CARC top coated as same color as specified for the stlr. FRPs shall have color incorporated directly into their base material.

d. When the racks are installed, the slats shall be inside the load space, with the upright stake posts on outside. The stakes shall be extruded aluminum, 6061-T6.

e. An opening shall be provided in each FRP panel to allow access to the small cargo rings. The exposed edge created by the opening shall be sealed and reinforced with an aluminum plate.

3.19.1 Detail requirements for side rack kit. The aluminum panels shall be reinforced at the top, bottom and each end. The aluminum panels shall be corrugated, ribbed or reinforced to provide stiffness. Individual panel sections shall be 4 feet wide and 4 feet high. The intermediate side sections shall be interchangeable on the same side, except for the adjusting sections. The cross section configuration on the vertical panel edges shall be such that adjoining panels will interlock or overlap. The panel tops shall be parallel with the platform surface and positively fastened together for alignment. Panels across the rear shall be provided. All panels shall be readily removable by hand and shall show no evidence of binding or jamming.

3.19.2 Top Rail of Panels. All panels to have top aluminum 6061-T6 rail that protects the panel. The top rail and panel to be painted before assembly. The top rail to have provisions for fork lift truck/hand removal/installation.

3.19.3 Reserved.

3.20 Tarpaulin Kit. When specified (see 6.2), stlr shall be provided with a kit with roof bows, a fitted tarpaulin and tiedown ropes. The roof bows shall be spaced on centers of not more than 48 inches.

3.20.1 Tarpaulin. The stlr shall be equipped with a one-piece tarpaulin. All stlrs shall be fitted with tarpaulin securing devices. The tarpaulin shall fit the stlr when the side and rear panels are installed. The tarpaulin material shall be vinyl-coated nylon conforming to type II, class 2 of MIL-PRF-20696 or equivalent. It shall cover the bows, side racks, and bulkhead such that when installed, there will be an approximate 24-inch drape over the front, rear and side panels. The front of the tarp shall be contour sewn, such that there is no opening at the corners, and shall form-fit the front end of the stlr. The rear end shall have plain corners that can be wrapped around the rear end and secured with heavy-duty shock straps. The tarpaulin color green or desert tan, as applicable, (dyed in fabric) shall be lusterless and have infrared reflectance properties as specified in MIL-DTL-53039.

3.20.2 Tarpaulin Details. The edges of the tarpaulin shall have 6-inch hems with three rows of stitching.

Heat-sealing of the hems is preferred over sewing in order to avoid puncturing the material and exposing thread to UV and other environmental deterioration over time. The tarpaulin shall have heavy-duty spur type grommets or D-rings all around the hem. One grommet shall be in each corner and the midpoint of the front and rear hems.

Grommets shall be evenly spaced approximately every two feet between the corner and midpoint grommets on all four edges. Commercial grommets or D-rings shall be corrosion resistant or zinc-plated steel, ¾-inch size, of forest green or black color.

3.20.2.1 Tarpaulin Details (Alternate): The edges of the tarpaulin shall have 2‖ double-wrapped hems reinforced with a vinyl insert and double stitching. The seams shall be sealed. Heat-sealing of the hems is preferred over sewing in order to avoid puncturing the material and exposing thread to UV and other environmental deterioration over time. The tarpaulin shall have heavy-duty spur type grommets or D-rings all around the hem. One grommet shall be in each corner and the midpoint of the front and rear hems. Grommets shall be evenly spaced approximately every two feet between the corner and midpoint grommets on all four edges. Commercial grommets or D-rings shall be corrosion resistant or zinc-plated steel, ¾-inch size, of forest green or black color.

3.20.3 Reserved.

3.20.4 Tarpaulin Ropes/Straps. A safety tiedown rope shall be provided on each long side of the tarp at the midpoint to retain the tarp if the shock straps should fail or disengage. A tarp tiedown rope shall be attached to the five grommets in the front of tarp. The tiedown ropes shall be polypropylene conforming to MIL-R-24049, type II, three strand, twisted, monofilament, 3/8 inch diameter, color black, approximately four feet long. A gable ridge rope 55 to 60 feet long, 3/8-inch diameter, three strand nylon, shall be provided to prevent sagging of tarp between bows. The nylon gable ridge rope shall be captive sewn into the tarpaulin along the inside center in such a manner as to allow longitudinal movement of a minimum of 12 inches. Rubber shock straps, with lengths as follows, shall be provided for all other grommets. Shock straps shall be nominal ¼ x ¾-inch size with ―S‖ hooks in each end. Shock straps shall function properly in temperatures from +125°F to -40° F.

3.20.4.1 Tarpaulin Ropes/Straps (Alternate): A safety tiedown rope shall be provided on each long side of the tarp at the midpoint to retain the tarp if the shock straps should fail or disengage. A tarp tiedown rope shall be attached to the five grommets in the front of tarp.