Attachment 5 - Appendix D - Rider Reach.docx

Solicitation Number:

FA8604-

-R-

FA488720Q0005

Attachment 5

1 OCTOBER 2019

APPENDIX D

FOR A

RIDER-REACH VEHICLE

AT

LUKE AFB ARIZONA

F-35 PARTS WAREHOUSE

DATE: 1 OCTOBER 2019

PREPARED BY:

___Andrew J. Huser____

ANDREW HUSER

PROJECT ENGINEER

AFLCMC/EZPAE

Table of Contents

LUKE AFB - APP D - Page i

SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for a rider reach-type vehicle in the F-35 Parts Warehouse at Luke Air Force Base (AFB), Arizona. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force Figure 1. This appendix is intended to cover all equipment, materials, and labor necessary to complete the installation of the system.

APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

REQUIREMENTS

System description The rider reach-type vehicles shall interface with the pallet rack (Appendix C) installed as shown in AF Figure 1 (Cover PD). The vehicle system shall consist of the following components:

a. One vehicle.

b. Battery system.

c. Conduit, wiring, mechanical fasteners and all other items required to install an operational vehicle system.

Physical and performance characteristics

System operation The vehicle will be used to handle, store and retrieve palletized loads and larger, wide-sized loads. The vehicles shall be capable of handling wooden pallets and larger outsized items in and out of the pallet rack specified in Appendix C. The vehicles shall be capable of operation within the 11’ aisles shown in AF Figure 1 (Cover PD).

Capacity The vehicle, with a 24-inch load center, shall have a capacity of 3,000 pounds to a lift height of 168 inches. Downrating of capacity is acceptable at upper limits of lift height.

Dimensional requirements Removal or insertion of pallets within minimum eleven-foot wide aisles with a minimum 12 inches clearance between the vehicle and the opposing rack shall be possible. The vehicles supplied shall conform to the following dimensions:

Minimum elevated fork height..........................168 inches

Elevated fork height not to exceed....................170 inches

Maximum overall extended height.......................218 inches

Travel characteristics Rate of travel The vehicle shall operate at continuously variable speeds in both the forward and reverse directions. Maximum travel speed shall be automatically decreased to a creep speed when the mast is raised above the first or free lift stage, or as approved by the CODR.

Drive motor control An electronic, solid state, silicon controller rectifier (SCR), or transistorized type, or equivalent as approved by the CODR, shall be used to govern vehicle travel speed. The drive motor control system shall have a safety interlock to cut out all travel in the event of controller malfunction. The speed control system shall provide stepless speed control in both forward and reverse directions. The controller shall permit the use of maximum power at low speeds and capacity load conditions.

Plugging The vehicle shall be capable of "plugging", whereby the operator can slow or stop the vehicle by reverse movement of the speed control.

Deadman brake A deadman type brake shall be furnished. Vehicle travel shall not be possible unless the deadman pedal is fully depressed. Upon release of the pedal, vehicle travel shall be immediately halted. The brake shall provide for separate actuation and shall be spring applied when the brake pedal is released. .

Load handling characteristics Lift/Lower speeds Lifting and lowering speeds shall be manufacturer’s standard speeds for lifting and lower, both loaded and unloaded. There shall be no pulsating or jerky movement of the fork carriage when being raised or lowered at any speed. The hydraulic control system shall be damped, metered, or automatically regulated to reduce shock and prevent instability of the vehicle when the maximum capacity load is raised or lowered at maximum speed and then stopped suddenly.

Masts Masts shall be the telescopic type. Means shall be provided in the mast to compensate, by adjustment or replacement, for wear which may develop between sliding surfaces or lateral rolling contacts. Upper and lower "limit stops" shall be provided to prevent overtravel. Cross members of the mast structure, when in a lowered position, shall not interfere with the operator's horizontal or downward line of sight.

Lift limit switch A lift limit switch shall be installed on each forklift to protect against the accidental impact of any forklift component with overhead fixtures such as lights, fire sprinklers, heaters, etc. The limit switches shall be adjustable at the installation site. The Contractor shall set the critical height based on the lowest existing obstruction over the aisles in which the forklift operates. A manual override button shall be provided on the control panel. To lift above the critical height, the override button must be depressed at the same time the lift control is activated. In addition, the forklift shall not be capable of lifting above the critical height, unless the override button is depressed.

Reach mechanism A pantograph type, hydraulic controlled reach mechanism shall be provided to extend the forks a minimum of 22 inches from the fully retracted position with a load of 3,000 pounds. In the fully extended position, the bend in the forks shall extend beyond the vehicle outriggers. The reach mechanism shall be capable of operating at all lifting heights with up to the rated capacity load. The center pivot of the reach mechanism shall be provided with lubricated and sealed-for-life roller bearings or equivalent as approved by the Contracting Officer or Designated Representative (CODR). The mechanism shall be provided with chrome plated hydraulic cylinder rods and shall have hydraulic cushions at each end of the stroke.

Fork carriage The fork carriage shall be equipped with a hydraulic controlled tilt mechanism, hydraulic controlled sideshift mechanism, and a load backrest. Tilt and sideshift mechanisms shall be designed to operate in all reach positions and at all lifting heights, with up to the rated capacity load.

Tilt mechanism A hydraulic controlled tilt mechanism shall be provided. The tilt mechanism shall be capable of a minimum 2 degree forward and 4 degree rearward tilt.

Sideshift mechanism A hydraulic controlled sideshift mechanism shall be provided. Sideshift mechanism shall be capable of positioning the fork carriage two inches to either the right or left of the center position. Total sideshift travel shall be four inches.

Load backrest The fork carriage shall be equipped with a load backrest. Load backrest shall be fabricated of steel and shall be a minimum 48 inches high.

Fork tines Fork tines shall be minimum 4 inches wide by 42 inches long. Forks shall be a minimum of 1-1/2 inches thick at the heel and taper to a minimum 1/4-inch at the tip. Fork spacing shall be adjustable between a minimum of 20 and 27 inches, measured outside-to-outside.

Hydraulic system All hydraulic power shall be furnished by pumps directly driven by electric motors independent of the drive motor. A filtration device shall be installed within the hydraulic system for continuous filtering of hydraulic fluid. Hydraulic valves, cylinders, and motors shall have means for preventing oil seepage from dripping or running onto electrical elements. The hydraulic system shall provide for smooth raising and lowering of the load. The lowering speed shall not exceed 110 feet-per-minute in the event of a hydraulic failure.

Hydraulic tank The storage tank shall be of welded steel construction or molded nylon and shall have a capacity not less than 125 percent of the amount of fluid required for the hydraulic system's operation. The tank and hydraulic system shall be capable of being drained without spillage and shall be provided with a means to protect against contamination of hydraulic fluid. The tank shall have sufficient capacity to prevent air from entering the hydraulic system with all hydraulic pistons fully extended. It shall have sufficient free air capacity to prevent oil from being discharged through the tank filler cap when maximum return flow of oil is surged into the tank from the system.

Lubrication Accessible means shall be provided for checking and adjusting the level of lubricant in all parts and components. Oil drain plugs shall provide for drainage using ordinary maintenance shop tools. Oil drain plugs and connectors shall be located to provide drainage without interference from frame members or other parts of the vehicle structure. Drain connections shall not require the use of flexible connections or other special devices.

Frame and body The frame and related structure shall be fabricated from steel structural shapes, plates, sheets, tubing, castings and forgings. The body shall be constructed of plate steel which encloses the drive unit assembly, steering mechanism, and speed controller. Provisions shall be made to allow quick and easy access to all working parts requiring maintenance and inspection. If hand access openings are provided, the edges of all openings shall be smooth and shall be provided with a removable or hinged cover.

Operator's compartment The flooring of the operator's compartment shall be a minimum size of 16+/-1 inches wide by 15+/-1 inches deep. The flooring shall have a nonskid, low-fatigue surface. The operator's compartment and controls shall be arranged so that no part of the operator's body shall extend beyond the outside plane of the vehicle during normal operation.

Overhead guard The operator's compartment shall be protected by a steel overhead guard which meets the requirements of ANSI B56.1. The overhead guard shall not interfere with the operation of the vehicle or operator access to the vehicle.

Battery compartment The battery compartment shall be provided with rollers for easy removal and replacement of the battery. The battery compartment shall be compatible to function with the battery handling system. Locking battery gates which are easily removable, without the use of hand tools, shall be provided. In addition, means shall be provided to secure the battery from shifting within the battery compartment. The battery compartment walls, top, bottom and rollers shall be protected with an acid-alkaline resistant material. Openings for battery leads shall not cut or chafe the cables. Vehicle components such as bearings or wiring that are easily damaged by battery electrolyte spillage or overflow shall be shielded. The battery compartment shall be provided with an adequate opening, providing easy access to service or replace the battery. Battery compartment shall be equipped with rollers for easy removal of batteries and with a locking battery gate to retain the battery during use.

Steering Power steering shall be provided. Steering shall be accomplished by a hand steering wheel or lever and shall be equipped with a steering knob for convenient operation. The drive assembly shall be capable of being turned from extreme right to extreme left, or vice versa, in not more than six turns of the steering wheel and/or six seconds with a maximum force of not more than 10 pounds when the vehicle is stationary and carrying a 3,000-pound load.

Wheels Drive, load, and idler wheels shall clear any part of the vehicle structure by at least 1/4-inch under all conditions of operation. The vehicle shall be equipped with a minimum 10-inch diameter drive wheel. Tandem load wheels shall be provided on each outrigger. Load wheels shall be a minimum of 4-inches in diameter. Readily accessible grease fittings or prelubricated sealed bearings shall be furnished to provide lubrication. Drive tires shall be non-marking solid rubber. Load wheels and casters shall be provided with polyurethane tires.

Controls Electrical controls shall conform to the applicable requirements of NEMA ICS 2. All controls shall be permanently marked to indicate function and direction. Fork carriage controls shall be located for simultaneous hand operation with spacing in accordance with MIL-STD-14720.

Control panel The control panel shall be designed for ready removal as a unit, or front removal of individual major components mounted thereon. The control panel cover shall be readily removable without interference from the vehicle structure or other major components.

Speed controller Speed and directional controls shall be provided for comfortable hand operation. Speed control shall be continuously variable. The controller shall provide means to permit precision maneuvering in restricted areas. Automatic means shall be provided to prevent current flow to the motor without first going through the successive accelerating steps in the sequence. Automatic means shall prevent reversal of direction except through first speed. Forward movement of the control shall cause the vehicle to go forward, and rearward movement of the control shall cause it to travel backward. Speed shall be restricted to a creep speed when forks are raised above the first stage or free lift stage, or as approved by the CODR.

Fork carriage controls Lift/lower, tilt, sideshift, and fork extension controls shall provide full feather operation of hydraulic cylinders for precise positioning of the load. Carriage controls shall be positioned on the vehicles control panel for easy operator access.

Instruments All gauges shall be products of manufacturers regularly engaged in producing instruments of this type. Gauges shall be flush mounted on a surface which is plainly visible to the operator.

Hour meter An electrically operated hour meter shall be provided on each vehicle to register cumulatively the duration of vehicle activity. The hour meter shall register a minimum of 9,999 hours and shall operate only when the deadman brake is depressed. The hour meter shall not be resettable.

Battery discharge indicator A solid state battery discharge indicator shall be installed on each vehicle to sense an 80 percent discharge condition of the battery. Each battery discharge indicator shall be equipped with a warning light to indicate the battery needs charging. The device shall inhibit lift capabilities when an 80 percent discharge condition exists.

Horn Each vehicle shall be equipped with a push button horn which is operable without requiring the operator to release the steering and speed controls.

Key switch A key switch shall be provided to turn the power to the vehicles on and off. Two keys shall be provided.

Warning light Each vehicle shall be equipped with a highly visible electronic red or amber flashing strobe light to provide visual warning to other traffic. The light shall be activated whenever the key switch is on. The warning light shall be positioned or guarded to protect it from damage.

Electrical characteristics Power source The Contractor shall run all required electrical from a Government-furnished power source located in the Mechanical Room as shown on Figure 1 (Cover PD). The Contractor shall furnish and install all necessary wiring and equipment for power distribution to the system in accordance with NFPA 70.

Electrical conductors Conductors passing through compartment walls or other metal barriers shall be protected in accordance with Article 300-4, NFPA 70 and shall be protected by loom, rubber hose, or equivalent as approved by the CODR. Conductors shall be securely anchored to prevent movement relative to the opening. An automatic take-up, positioned to prevent interference with the normal vehicle operation, shall be provided on the mast or body to eliminate slack in the control cable.

Motors Drive motors shall be series or compound wound, heavy duty, industrial type, with a high starting torque. As a minimum, motors shall be provided with Class H rated insulation. The hydraulic pump motor capacity shall be sufficient to lift 3,000 pounds at speeds specified herein.

3.3.4 BATTERY SYSTEM

The vehicle shall be provided with one battery. One compatible battery charger shall be provided with the battery. When a discharged battery must be charged, the vehicle shall be positioned adjacent to the battery charger and the charging cables attached to the battery. The battery and charging equipment shall be a minimum 24-volt system.

3.3.4.1 BatterY

The vehicle shall be supplied with a lead-acid battery. A fully charged battery shall be capable of operating the vehicle for a minimum of eight hours under normal or continuous operating conditions. The battery shall be rated at a minimum of 24 volts. Battery casings shall be heat sealed or equivalent as approved by the CODR to provide a leak-proof housing. Battery weight shall be within the vehicle manufacturer's recommended range.

3.3.4.2 Battery charger

One compatible battery charger shall be furnished for the vehicle. The charger shall be the rectifier type to prevent overcharging of batteries. The charger shall supply a charge to the battery capable of powering the vehicle for eight hours of continuous operation. The charge shall reduce to a trickle charge once the battery is fully charged. Charger shall be provided with an equalizing feature to bring all battery cells to the same charge level. The battery charger shall be designed in accordance with NEMA IB 6. The charger supply voltage shall be designed to operate on the electrical characteristics as they exist at the site. Battery charger shall be mounted on a cantilever type stand in the location determined by Base Project Officer.

3.3.4.3. Battery charging stand

The battery charger shall be securely fastened to a battery charging stand. Battery charging stand shall be securely anchored to the warehouse floor in the location determined by Base Project Officer.

3.3.4.4. Battery connectors.

The vehicle shall be equipped with connectors to connect the battery to the truck circuit and to the battery charger. Connector halves shall be color coded, labeled or marked to clearly indicate polarity. Connector halves shall be constructed to permit only proper connection of polarities. A manually operated quick disconnect mechanism shall be provided on the vehicles to break the power circuit if necessary.

3.3.4.5. Non conductivity of racks.

Racks used for the charging of batteries shall adhere to the requirements of CFR 1910.178(g).

3.3.4.6. Resistance to electrolyte.

The vehicle battery compartment, including the sides, top and roller mechanism shall be treated to protect against corrosion resultant of electrolyte spillage. In addition, battery transfer equipment and charging stands shall be treated to protect against corrosion from electrolyte spillage. Surfaces shall be treated in accordance with OSHA 1926.403 (a) 3 & 4.

QUALITY ASSURANCE PROVISIONS

4.1 INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the Cover PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2 TESTS.

The following tests shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No.

LUKE AFB - APP D - Page 12

LUKE AFB - APP D - Page 11

TECHNICAL QUOTE QUESTIONNAIRE

FOR

RIDER-REACH VEHICLE

Appendix D, Rider-Reach Truck, 1 OCTOBER 2019

This questionnaire shall be completed by the Offeror. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment. Please attach product literature/cut sheets for all equipment detailed in this questionnaire and attach any exceptions to the Purchase Description Appendix or recommendations/design alternatives as detailed below.

Rider-Reach Truck Manufacturer: ______________________________ Model Number: ________________________________________________

3.1

3.2.2.

Number of vehicles provided: ____________

Truck capacity: ______ pounds

3.2.3.

Minimum elevated fork height: _____ inches

Elevated fork height not to exceed: _____ inches

Maximum overall extended height: _____ inches

Fork spacing is adjustable between _____ inches and _____ inches.

Width: ______ inches Depth: ______ inches

3.2.11.1.

Are hour meter and battery discharge indicators provided as specified?

3.2.13

3.2.14.

Is a key switch with two keys provided?

Is a warning light provided as specified?

3.3.4.2.

Battery charger:

Manufacturer: __________________________________ Model Number: __________________________________

EXCEPTIONS

Attach any exceptions taken to the Purchase Description Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken?

EXCEPTIONS:

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