Amendment 1_ APPENDIX A - 60 LRS Turret Truck updated.pdf

Travis AFB, Appendix F - Page i

APPENDIX A

SPECIFICATIONS

FOR

WIRE-GUIDED MAN-UP TURRET TRUCK SYSTEM

AT

60 LRS, BUILDING 549

TRAVIS AIR FORCE BASE, CA

Travis AFB, Appendix A - Page 2

1. PERFORMANCE CHARACTERISTICS

1.1 SYSTEM OPERATION

The operator compartment of the turret truck shall be adjacent to the forks and designed for unobstructed movement of materials during stock picking. The turret truck will be used as a swing-reach forklift. Pallet loads shall be capable of being rotated within the aisle. The turret truck shall be capable of operating in manual mode in 70-inch pallet rack aisles (face-to- face) by means of wire-guidance. The turret truck shall be positioned to interface with the guidance system, by manual control, before entering the aisle. The turret truck steering shall be automatically controlled in the aisle. Pallet positioning in the pallet rack shall be through the use of the turret truck's primary and auxiliary masts.

1.2 CAPACITY

The turret truck, with a 24-inch load center, shall have a minimum capacity of 3,000 pounds to full lift height.

1.3 RATE OF TRAVEL

The turret truck shall operate at continuously variable speeds in both the forward and reverse directions. With the operator's platform below 36 inches, the turret truck shall have a speed of

5.0 + 2 miles per hour (mph) when unloaded and a minimum speed of 3.0 mph when loaded to 3,000 pounds. With the rated load or empty, interlock switches shall limit travel speed of the turret truck to 2.0 + 0.2 mph when the operator's platform is greater than 30 + 6-inches above the floor.

1.4 LIFTING/LOWERING SPEED

Lifting and lowering speeds at rated load shall be as specified below. There shall be no pulsating or jerky movement of the carriage when being lifted or lowered at any speed. The hydraulic control system shall be damped, metered, or automatically regulated to reduce shock when the rated load is lifted or lowered at maximum speed and then stopped suddenly.

Minimum Maximum

Primary Mast Lifting Speed

(with rated load)

45 ft/min N/A

Primary Mast Lifting Speed

(unloaded)

56 ft/min N/A

Travis AFB, Appendix A - Page 3

Primary Mast Lowering Speed

(with rated load)

30 ft/min 100 ft/min

Primary Mast Lowering Speed

(unloaded)

30 ft/min 100 ft/min

1.5 STABILITY

As a minimum, the turret truck shall meet ANSI B56.1A general stability criteria. The operator's compartment shall not sway excessively when positioning the rated load at full elevation height. The drive wheels and load wheels shall be designed for maximum stability of the turret truck and appropriate weight distribution on the floor. The suspension system shall compensate for irregularities in the floor and provide stability. A simple drag point suspension system shall not be acceptable.

1.6 TURRET TRUCK GUIDANCE

The turret truck shall be capable of manual and wire-guided steering.

1.6.1 MANUAL STEERING

Power steering shall be provided. A hand operated steering crank shall accomplish steering or a round steering wheel equipped with a steering knob for convenient operation. The steering assembly shall be capable of being turned from extreme right to extreme left, or vice versa, in not more than six turns of the hand steering crank/wheel. A maximum force of 10 pounds shall be required to turn the steering wheel when the turret truck is stationary and carrying a 3,000-pound load. A drive wheel indicator shall be provided to indicate the direction in which the drive tire is turned at all times.

1.6.2 WIRE GUIDANCE SYSTEM

The wire-guidance system shall consist of the following:

1.6.2.1 WIRE-GUIDED STEERING

Each truck shall be capable of being automatically guided along a wire embedded in the floor. Each truck shall be capable of acquiring the signal from the wire before the truck enters the storage aisles and shall ensure the trucks are positioned for proper aisle entry without damage or displacement of storage aids or material. The truck shall exhibit this capability regardless of whether entry into a storage aisle is accomplished in the forward or rearward direction. When in the guidance

Travis AFB, Appendix A - Page 4 mode, the truck shall operate in a path that does not deviate more than 1-1/2 inches from its center position to either side of the directed path. When the truck varies more than 1-1/2 inches from the center position, it shall slow down to creep speed automatically. Note: Creep speed is defined as the slowest forward or backward speed attained under automatic truck guidance. Manual steering capabilities shall be disabled while under wire-guidance mode. A safety interlock shall be provided which shall bring the truck to a smooth, controlled stop should the truck, for any reason, lose the guidance signal. This safety interlock shall also stop the truck automatically if it deviates more than 3 inches from center position.

1.6.2.2 WIRE-GUIDANCE INDICATOR

A switch shall be provided to activate the truck's wire-guidance system and shall be guarded to prevent accidental activation or deactivation. A light shall also be provided to inform the operator, when in the wire-guidance mode, that the vehicle has acquired the signal. A wire signal monitor shall be provided to stop the truck and sound an audible alarm when the signal is lost or the vehicle leaves the wire.

1.6.2.3 LINE DRIVER

The line driver shall transmit a signal through the guide wire for movement of the vehicles in the automatic steering mode.

The line driver shall be securely fastened to the building wall or column and located so as to minimize the possibility of physical damage. The line driver shall be equipped with a battery back-up for a minimum of eight hours of operation. In the event of a power failure, the line driver shall automatically switch to the battery back-up.

1.6.2.4 GUIDE WIRE INSTALLATION

All guide wires shall be embedded at a depth of 5/8 + 1/8 inch.

All sharp corners shall be curved to prevent stress points during wire expansion and contraction. At all concrete slab junctions, expansion joints, and any other points where movement may occur, a stress relief loop shall be provided to prevent wire breakage and shall be covered with a non-hardening material

(RTV silicone or approved equivalent) a minimum of 2 inches in both directions from the joint. The Contractor shall fill the remaining guide path with epoxy or an equivalent non-shrinking grout material, level with the floor to exclude dirt and debris.

Travis AFB, Appendix A - Page 5

All splices and junctions shall be clearly identified on as-built drawings for future trouble-shooting reference. The guide wires shall be connected to the Contractor-furnished line driver.

1.6.2.5 CONCRETE DUST CONTROL

Cutting of concrete floors for wire installation shall be accomplished by using a liquid spray to minimize dust generation. The solution shall be vacuumed up during the cutting process to minimize dust pollution and prevent water supply contamination. Proper disposal of all waste, solution, and residual concrete dust shall be the responsibility of the

Contractor.

1.7 FORK ROTATION

The carriage shall traverse to permit the forks, fully loaded with a palletized load, to rotate and move laterally across the width of the load handler while within a storage aisle. The forks shall rotate 180 degrees on a vertical axis at any height such that the forks face either side of the aisle.

1.8 INTERFACING WITH STORAGE POSITIONS

The turret truck shall be capable of interfacing with the pallet rack located in Building 549. The operator shall be capable of storing or retrieving pallet sized loads and containers into or out of the pallet rack without being hindered by any of the turret truck's components. The turret truck shall be equipped with sufficient "reach" and "side-shift" capability to permit complete interface with loads within the storage system or loads located on the floor. The reach feature shall permit the front face of the forks to extend a minimum of 4 inches beyond both sides of the turret truck (forks rotated to extreme right and rotated 180 degrees to extreme left) or any traversal point between the extreme right and extreme left.

1.9 DIMENSIONS

Each turret truck shall be capable of operating in a 70-inch aisle with a minimum clearance of 7 inches between each side of the turret truck and the pallet rack face. The turret truck supplied shall conform to the following dimensions:

Minimum elevated fork height using auxiliary mask

148 inches

Travis AFB, Appendix A - Page 6

Maximum collapsed height 120 inches

Maximum overall cab height

(extended)

168 inches

Maximum lowered fork height 2-1/2 inches

1.10 FORK DIMENSIONS

Forks shall be minimum 3-1/2 inches wide by minimum 36 inches long, forged steel. The forks shall be a minimum 1-1/4 inches thick at the heel and taper to a minimum 1/2-inch thick at the tip. Fork spacing shall be adjustable, in not greater than 2-inch increments, within a range from 19 to 29 inches, measured outside to outside.

1.11 FRAME AND BODY

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

1.12 LOAD BACKREST

A metal backrest shall be provided. It shall be 31-1/2 inches to 44 inches high measured from the load-carrying surface of the forks. It shall have sufficient strength and width to support the rated load when the turret truck is at maximum rearward tilt. Backrest design shall not obstruct operator's visibility.

The spacing between vertical members shall not exceed 8 inches.

1.13 BATTERY COMPARTMENT

The battery compartment shall be provided with rollers for easy removal and replacement of the battery. The battery compartment shall be compatible with and function with the battery handling system. Battery gates, which are easily removable with simple hand tools, shall be provided. The battery compartment shall hold the battery securely without damaging the battery. The

Travis AFB, Appendix A - Page 7 walls, the top, and the bottom of the battery compartment shall be protected with an acid-alkaline resistant material. Openings for battery leads shall not cut or chafe the cables. Turret truck components, such as bearings and wiring, easily damaged by battery electrolyte spillage or overflow, shall be shielded.

1.14 OPERATOR'S COMPARTMENT

The operator's compartment shall be able to raise and lower on the primary mast. The compartment shall provide the operator with an unobstructed view of the forks, load, and pallet rack beams at all heights, and particularly during the storing and retrieval operation. The operator's compartment shall be fabricated from steel plate and shall be designed for unobstructed egress from the compartment while in the storage aisle. The equipment and controls shall not require any part of the operator's body to extend beyond the outside plane of the turret truck during normal operations. The floor of the compartment shall be at least 50 inches wide by 19 inches deep.

A nonskid, low-fatigue surface or mat shall be provided for the floor.

1.14.1 OVERHEAD GUARD

The operator's compartment shall be protected by a steel overhead safety guard, which meets the requirements of ANSI

B56.1A. The overhead guard shall not interfere with the operation of the turret truck, nor the drivers entering or leaving the turret truck. The overhead guard shall provide an anchorage point for the safety harness, meeting the requirements of AF Manual 91-203. Signage next to the anchorage point shall indicate it supports a minimum of 5,000 pounds.

1.14.2 SIDE RAILS

Side rails for operator restraint shall be in accordance with

ANSI B56.1A and shall be capable of withstanding a concentrated horizontal force of 200 pounds without permanent deformation.

Side rail lockout devices shall be provided on each turret truck to ensure that the turret truck will not operate unless the side rails are in the horizontal position. The side rails shall be hinged so that they can be raised and locked in the raised position. The rails shall not offer a pinching hazard or restriction to movement of material between the turret truck and the pallet racks.

1.14.3 SEAT

Travis AFB, Appendix A - Page 8

A folding seat shall be provided to allow operation from a sitting or standing position. The seat shall have a cushioned bottom and backrest and shall be adjustable up and down.

1.14.4 FANS

On each side, accessible to the operator, the operator's compartment shall be provided with a heavy-duty 6 to 7-inch diameter electric fan to provide air circulation for the operator. The fans shall be on adjustable mounts, with finger guards and on-off switches.

1.14.5 TURRET TRUCK MAST PROTECTION

An impact resistant, clear Plexiglas or equivalent or polycarbonate window or wire mesh shall be mounted between the operator's compartment and the turret truck mast providing the operator with full protection from all moving parts in the mast.

The window or wire mesh shall be positioned so as to block the operator, or any part of his body, from extending into the mast area. The window or mesh shall not obstruct the vision of the operator.

1.15 MASTS

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 over travel.

1.15.1 PRIMARY MAST

The primary mast shall be of the telescopic type. Cross members of the mast structure, when in a lowered position, shall not interfere with the operator's horizontal or vertical line of sight.

1.15.2 AUXILIARY MAST

The auxiliary mast shall have the capability to raise and lower the rated load, independent of the primary mast.

1.16 WHEELS

Drive, load, and idler wheels shall clear any part of the turret truck structure by at least 1/4 inch under all conditions of operation. Readily accessible grease fittings or pre-lubricated sealed bearings shall be furnished to provide lubrication. All

Travis AFB, Appendix A - Page 9 tires shall be non-marking, solid polyurethane or non-marking, solid rubber molded onto a steel band pressed onto flat-faced wheels.

1.17 LUBRICATION

Accessible means shall be provided for checking and adjusting the level of lubricant in all parts and components. Oil drain plugs and connections 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 turret truck structure. Drain connections shall not require the use of flexible connections or other special devices.

1.18 DEADMAN BRAKE

The system shall be so designed that the operator must depress the deadman pedal before any turret truck activity can be initiated horizontally. A deadman brake shall be furnished and shall be a mechanical friction brake acting directly on the steerable wheel or any shaft positively connected to the steerable wheel. It shall provide for separate actuation and shall be spring applied when the brake pedal is released. The braking system shall be interlocked with a switch(es) which shall interrupt the electrical current to the drive motor(s) when the deadman brake is actuated. The brake pedal, when depressed to fully release the brake, shall be in a horizontal position and flush with the floor of the operator's platform.

The pedal shall not project more than 3 inches above the floor of the operator's platform with the deadman brake fully applied.

Force required holding the pedal fully depressed shall not exceed 20 pounds. The deadman brake pedal shall be provided with a rubber covering. The deadman brake shall be at least 3-

3/4 inches wide and at least 6 inches long or equivalent as approved by the Contracting Officer’s Technical Representative

(COTR). The deadman brake shall be protected to ensure satisfactory operation and shall provide for ready and immediate servicing and adjustment.

1.19 PLUGGING

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

1.20 HYDRAULIC SYSTEM

Travis AFB, Appendix A - Page 10

All hydraulic power shall be furnished by pumps directly driven by electric motors independent of the drive motors. 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 160 feet per minute in the event of hydraulic failure.

1.20.1 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.

1.20.2 OVERLOAD VALVE

The hydraulic system shall be equipped with an overload valve to prevent overloading. The pressure relief valve shall open when pressure exceeds no more than 110 percent of the maximum pressure required to lift a 3,000 pound load.

1.20.3 AUXILIARY LOWERING CONTROL

The turret truck shall have an auxiliary lowering control to lower the lift platform to ground level in case standard lowering procedures have failed. The control shall be accessible from ground level and shall not require the use of tools for access or operation. The lowering speed shall be limited to a range of 40 feet per minute to a maximum of 100 feet per minute under maximum load.

1.21 SAFETY HARNESS

In accordance with AFI 91-234, the turret truck shall be equipped with a full body harness to protect personnel from accidentally falling off the platform. The safety harness shall not interfere with the placement of material into or out of the module by the operator or with the operation of the turret truck.

Travis AFB, Appendix A - Page 11

1.22 FIRE EXTINGUISHER

The turret truck shall be equipped with a fire extinguisher of

UL Classification 3 to 20 A and 30 to 80 B: C, or an approved equivalent. Each extinguisher shall be mounted for easy access in the operator's compartment. The fire extinguisher shall not interfere with the operator or the operation of the turret truck.

2. ELECTRICAL CHARACTERISTICS

2.1 POWER SOURCE

The Government-furnished power source is shown on AF Drawing

Attachment 1b. A quick disconnect distribution panel/switch shall be furnished and installed by the Contractor on the wall adjacent to the battery charging area for the battery charger.

The Contractor shall furnish and install all necessary wiring and equipment for power distribution to the system in accordance with NFPA 70.

2.2 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 COTR. Conductors shall be securely anchored to prevent movement relative to the opening.

An automatic take-up, positioned to prevent interference with normal turret truck operation, shall be provided on the mast or turret truck body to eliminate slack in the control cable.

2.3 MOTORS

Drive motors shall be alternating current (AC) motors, heavy duty, industrial type, with a smooth starting. The hydraulic pump motor capacity shall be sized to lift the rated loads at speeds specified herein.

2.4 CONTROLS

Electrical controls shall conform to the applicable requirements of NEMA ICS 2. All controls shall be permanently marked.

Controls shall be located for simultaneous hand operation with spacing design based on human engineering ergonomic principals.

Controls shall be located so they cannot be accidentally activated. The turret truck shall be capable of simultaneous vertical and horizontal travel.

Travis AFB, Appendix A - Page 12

2.4.1 SPEED CONTROLLER

Speed and directional controls shall be provided for comfortable hand operation. Speed control shall be continuously variable.

The speed controller shall provide means to permit precision maneuvering in restricted areas. Forward movement of the control shall cause the turret truck to go forward, and rearward movement of the control shall cause it to go backward.

2.4.2 LIFT/LOWER, REACH, AND PIVOT CONTROLLERS

Controls for fork and mast movement shall be self-centering and positioned for easy access on the turret truck control panel.

Lift/lower controls shall provide continuously variable lift and lower speeds (or not less than two speeds) required for precision positioning of the load. Lift/lower control shall provide for lifting and lowering the forks without the operator having to release the steering control, or utilize body parts other than hand, to operate the control.

2.5 CONTROL PANEL

The control panel shall be designed for removal as a unit, or front removal of individual major components mounted thereon.

The control panel and/or panel cover shall be readily removable without interference from the turret truck structure or other major components. All fastening devices shall be recessed in the panel.

2.6 INSTRUMENTS

All gauges and meters shall be products of manufacturers regularly engaged in producing instruments of this type. The instruments shall be flush mounted in the control panel, conveniently located, and plainly visible to the operator standing or sitting in the compartment.

2.6.1 HOUR METER

An electrically operated hour meter shall be provided to register cumulatively the duration of turret truck movement.

The hour meter shall not be resettable. The hour meter shall register a minimum of 9,999 hours. The hour meter shall be located on the control panel. The hour meter shall operate only when the motors are operating.

2.6.2 BATTERY DISCHARGE INDICATOR

Travis AFB, Appendix A - Page 13

A solid state battery discharge indicator shall be installed on the turret truck showing battery charge condition at all times.

The battery discharge indicator shall be equipped with a warning light to indicate the battery needs recharging. The device shall inhibit lift capabilities when an 80 percent discharge condition exists.

2.7 LIFT LIMIT SWITCH

A lift limit switch shall be installed on the turret truck to protect against the accidental impact of any turret truck component (i.e., the operator compartment or the load on the forks) with hanging fixtures such as lights, heaters, fire sprinklers, gas lines, or steam lines. The limit switch 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 turret truck operates. A manual override button shall be provided on the control panel. The turret truck shall not operate in the horizontal direction above the critical height. To lift above the critical height, the override button shall be depressed at the same time the lift button is depressed.

2.8 KEY SWITCH

A key switch shall be provided to energize and de-energize the turret truck electrical circuits. Key switches shall be keyed alike and two keys per turret truck shall be provided.

2.9 HORN

The turret truck shall be equipped with a push button electric horn, which is operable without requiring the operator to release the steering or speed controls.

2.10 TURRET TRUCK LIGHTING

2.10.1 RACK LIGHTING

Incandescent lights shall be provided to illuminate the rack face at a height three feet above the floor of the operator cab with a minimum of 50 foot candles. They shall illuminate the rack location where the work is to take place. A manual switch shall be provided on the control panel or the light itself that can turn the lights on or off. The light shall be positioned so that the load being carried does not interfere with lighting of the rack.

Travis AFB, Appendix A - Page 14

2.10.2 OPERATOR COMPARTMENT LIGHTING

Dome lights on each turret truck shall illuminate the operator's compartment a minimum of 25 foot-candles. The measurement shall be taken from a flat surface three feet above the platform floor. A manual switch shall be provided on the control panel or the light itself that can turn the lights on or off.

2.10.3 WARNING LIGHT

The turret truck shall be equipped with a highly visible electronic red/amber flashing light that shall 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.

2.10.4 AISLE LIGHTING

Each turret truck shall be provided with an aisle light, which illuminates the aisle in front of the vehicle (the end opposite the forks) at 30 foot-candles 10 feet in front of the turret truck. A manual switch shall be provided on the control panel that can turn the light on or off.

3.0 BATTERY SYSTEM

The battery charging system for the turret truck shall consist of the on-board battery of the vehicle, one-battery charger, a battery charging stand, and one portable eyewash station. At the end of a shift, the operator shall pull the turret truck up to the charger, disconnect the on-board battery cables from the battery, and plug them into the battery charger cables coming from the charger. Power for the charging area shall be drawn from the government power source shown on AF Drawing (Attachment

1b). 240 volt power is available in the power panel.

3.1 BATTERY

The turret truck shall be provided a lead acid battery. Each battery shall be rated at a minimum of 24 volts and shall have a minimum ampere-hour capacity for a continuous full eight hours of operation without recharging or replacement. Battery casings shall be heat-sealed or equivalent as approved by the COTR to provide a leak-proof housing. Battery weight shall be within the turret truck manufacturer's recommended range.

3.2 BATTERY CHARGER

Travis AFB, Appendix A - Page 15

One battery charger shall be provided with the system. The charger shall be rectifier type to prevent overcharging of the battery. The charger shall supply a charge to the battery capable of powering the turret truck for eight hours of continuous operation. The charger shall reduce to a trickle charge once the battery is fully charged. The charger shall be equipped with automatic means to prevent overcharging of a partially or fully charged battery. A button or switch shall be provided so that an equalized charge can be placed on the battery. The charger shall be designed to operate on the electrical characteristics as they exist at the site. The charger shall be anchored to the proper stand.

3.3 BATTERY CONNECTORS

The turret truck shall be equipped with connectors to connect the battery to the turret truck’s 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 turret truck to break the power circuit if necessary.

3.4 EYEWASH

An eyewash facility shall be installed as located on AF Drawing

(Attachment 1b). The eyewash shall be the self-contained, gravity fed type, providing for 15 minutes of continued operation. The eyewash shall be the portable type and shall be anchored to the proper stand.

3.5 BATTERY CHARGING AND EYEWASH STAND

The battery charger shall be securely fastened to the battery charging stand. The battery charging stand and the eyewash stand shall be securely anchored to the warehouse floor, as shown on Attachment 1b.

3.6 RESISTANCE TO ELECTROLYTE

The forklift battery compartment, including the sides, top and roller mechanism shall be treated to protect against damage due to electrolyte spillage. Surfaces shall be treated in accordance with OSHA 1926.403 (a) 3-4.

3.7 NON-CONDUCTIVITY OF RACKS

Travis AFB, Appendix A - Page 16

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

3.8 FORKLIFT GUARD POSTS

Steel pipe forklift guard posts shall be provided at the end of the rows and next to the door as shown on AF Drawing (Attachment

1b). The guard posts shall extend a minimum 3 feet above the floor and shall be installed in such a manner that they do not interfere with the normal usage of the turret truck. A cap shall be installed on the top of the guard post. Each forklift guard post shall be anchored to the floor with a minimum of four anchor bolts. The guard post shall be painted safety yellow.