Boom_Lift__-_Performance_Specifications_-_MIL-PRF-83812D.pdf

Comments, suggestions, or questions on this document should be addressed to 642 BSG/GBEC, 460 Richard Ray Blvd, Suite 200, Robins AFB, GA 31098-1813. Since contact information can change, you may want to verify the currency of this address information using the ASSIST

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DISTRIBUTION A. Approved for public release; distribution is unlimited

MIL-PRF-83812D

11 NOV 2011

SUPERSEDES

MIL-PRF-83812C

08 Aug 2006

PERFORMANCE SPECIFICATION

FORKLIFT, TRUCK, 10,000 AND 13,000 POUND CAPACITY, ADVERSE TERRAIN

This specification is approved for use by the Department of the Air Force and is available for use by all Departments and Agencies of the Department of Defense

1. SCOPE.

1.1 Scope. This document covers a standard commercial, diesel-engine, four wheel drive, adverse terrain forklift truck, which is air-transportable in C-130, C-17 and C-5 aircraft. The truck will be used primarily to load and unload palletized cargo to and from military aircraft.

It will also be used to handle loads of various sizes and weights, up to the rated load. The truck will operate on hard paved surfaces, soft soil, mud, snow, and sand, on level and hilly terrain.

1.2 Classification. The forklifts should be one of the following types as specified (see 6.2):

Type I - 10,000 pound capacity at 48 inch load center

Type II - 13,000 pound capacity at 54 inch load center

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

INCH – POUND

2.2.1 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 issues of these documents are those cited in the solicitation or contract.

FEDERAL STANDARD

FED-STD-595/14052 Green, Gloss

FED-STD-595/30313 Brown, Lusterless

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Identification Marking of US Military Property

MIL-STD-209 Lifting and Tiedown Provisions

MIL-STD-461 Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment

MIL-STD-810 Environmental Engineering Considerations and Laboratory

Tests

MIL-STD-1366 Transportability Criteria MIL-STD-1472 Human Engineering

DEPARTMENT OF DEFENSE SPECIFICATION

MIL-DTL-25959 Tiedown, Tensioners, Cargo, Aircraft

MIL-DTL-6458 Chain Assemblies, Single Leg, Aircraft Cargo Tiedown

MIL-DTL-83133 Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO

F-34), NATO F-35, and JP-8+100 (NATO F-37)

MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon

Base, Metric, NATO Code Number H-537

COMMERCIAL ITEM DESCRIPTIONS

A-A-52557 Fuel Oil, Diesel; For Posts, Camps and Stations.

A-A-59295 Corrosion Preventative Compounds, Cold Application.

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-1791 Designing For Internal Aerial Delivery in Fixed Wing

Aircraft.

NATO STANDARDIZATION AGREEMENT (STANAG)

STANAG 2828 Military Pallets, Packages, and Containers

. (Copies of these documents are available online at www.assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA

19111-5094.)

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

2.3 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 are those cited in the solicitation or contract.

AMERICAN WELDING SOCIETY (AWS)

AWS D14.1/D14.1M

(AWS documents may be obtained at www.aws.org or from American Welding Society 550 N.W.

LeJeune Rd., Miami, FL 33126)

INDUSTRIAL TRUCK STANDARDS DEVELOPMENT FOUNDATION (ITSDF)

ANSI/ITSDF B56.6-2005 Safety Standard for Rough Terrain Forklift Trucks

(ITSDF documents may be obtained at http://www.itsdf.org/ or from Industrial Truck Standards

Development Foundation, 1750 K Street NW, Suite 460, Washington DC 20009)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 3471 Earth-moving Machinery-Roll-Over Protective Structures, Laboratory Tests and Performance Requirements

(Electronic copies of this document are available from http://www.iso.ch or International

Organization for Standardization, American National Standards Institute (ANSI), Inc., P.O.

Box 2900, Fairfield, NJ 07007)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J98 Personnel Protection for General Purpose Industrial Machines

SAE J185 Access Systems for Off-Road Machines

SAE J386 Operator Restraint System for Off-Road Work Machines SAE J1176 External Leakage Classifications for Hydraulic Systems

(SAE documents may be obtained at www.sae.org or from Society of Automotive Engineers Inc., 400 Commonwealth Drive, Warrendale, PA 15096)

TIRE AND RIM ASSOCIATION, INC. (TRA)

Tire and Rim Association Yearbook http://www.itsdf.org/

(Application for copies should be addressed to the Tire and Rim Association, Inc., 175 Montrose

West Ave. Suite150, Copley, OH 44321)

UNDERWRITERS LABORATORIES INC.

UL 299 Dry Chemical Fire Extinguishers

UL 711 Rating and Fire Testing of Fire Extinguishers

(UL documents may be obtained at http://ulstandardsinfonet.ul.com/catalog or hardcopies and

CD’s can be found at COMM 2000 1414 Brook Drive, Downers Grove, IL 60515)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specified exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), one forklift sample shall be subjected to first article inspection in accordance with 4.2.

3.2 Forklift description. The forklift shall be the supplier’s standard, commercial, rigid or articulated frame forklift, or a front end loader modified with a forklift attachment in place of the scoop bucket. If the forklift is rigid frame type, it shall have operator selected 2-wheel/4-wheel crab steering, and operator selected 2-wheel/4-wheel drive. If the forklift is the articulated frame type, it shall have operator selected 2-wheel/4-wheel drive, except as noted (see 3.9.2).

Whatever type is furnished, it shall meet all requirements specified in this document. The forklift shall be air transportable in C-130, C-17 and C-5 aircraft, as a reference only, refer to

MIL-HDBK-1791. The forklift shall be equipped with, but not limited to, instruments, components and accessories that are standard on the commercial product, whether specified herein or not.

3.3 Design and construction. The forklift shall be designed and constructed so that no parts will work loose in service. They shall be built to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. They shall be weatherproof and designed to prevent the intrusion of water and sand into critical operating components.

Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be in intimate contact with each other.

3.3.1 Materials, protective coatings, and finish.

3.3.1.1 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the item shall not be used or shall have means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used.

Fasteners, handles, and fittings used in the assembly of the item shall also be primed and painted.

3.3.1.2 Tropical rust proofing. When specified (see 6.2), tropical rust proofing shall be provided.

This should be considered a premium rust proofing package usually consisting of an additional coating. The forklift shall be treated with a corrosion preventative compound complying with

A-A-59295. Many of these vehicles are used in tropical/coastal environments and experience high humidity and salt spray. Therefore, they usually exhibit high levels of corrosion in the areas listed below. At a minimum, these areas shall be coated:

a. Cab, interior

b. Cab, exterior

c. Seams

d. Welds

e. Hidden recessed areas

f. Locations where dissimilar metals come in contact

g. Area above fuel tank(s)

h. Engine oil pan & transmission oil pan

i. Radiator support structure

j. Battery box

3.3.1.3 Preparation and primer. All surfaces normally painted by the forklift manufacturer shall be prepared and primed using procedures compatible with the final paint.

3.3.1.4 Finish. The exterior finish color of the forklift shall be a standard, commercially available, polyurethane, closest to gloss green color number 14052 of FED-STD-595. If the manufacturer has a process that is more durable than polyurethane top coat and is willing to certify the process for the warranty period, it is acceptable. When specified (see 6.2), the final paint shall be standard, commercially available, polyurethane, closest to no-gloss tan color number 30313 of FED-STD-595.

3.3.2 Markings. Markings must be made with paint. Markings for green forklifts shall be black paint, and tan forklifts shall be white paint. The following markings shall be applied in the indicated locations:

a. Vehicle capacity (“10,000 POUNDS” for Type I or “13,000 POUNDS” for Type II) in

1-1/2 inch high letters on the lifting arms, mast, or front of forklift

b. “NO RIDERS” in 2 inch high letters on each side of forklift

3.3.3 Identification and information plates.

3.3.3.1 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the forklift in a readily accessible location. The identification plate shall contain the following information: nomenclature, make and model, manufacturer’s serial number (VIN), registration number, asset NSN number, vehicle curb weight (lbs), maximum payload (lbs), gross vehicle weight (lbs), delivery date, manufacturer’s name, Commercial and

Government Entity (CAGE) code, date of warranty expiration, contract number, and “US

Property”.

3.3.3.2 Transportation data plate. A transportation data plate shall be securely attached to the forklift in a readily accessible location. The plate shall contain at least the following information:

a. Side and rear silhouette views of the forklift

b. Horizontal and vertical location of the center of gravity of the forklift in air transportable configuration, marked on the silhouette views

c. Shipping weight (pounds)

d. Loading cubage (inches^3)

e. Overall height, width, and length (inches)

f. Front and rear axle loads (pounds)

g. Tiedown information

3.3.3.3 Instruction plates. All warning and instruction plates normally installed by the forklift manufacturer, describing procedures or safety items shall be included.

3.3.4 Safety. The forklift shall conform to the applicable requirements of

ANSI/ITSDF B56.6-2005, SAE J98, and OSHA standards in effect at the time of issue of the solicitation. All surface areas subject to personnel standing or walking shall have a nonskid, tread-plate, or expanded metal surface. A commercial fire extinguisher shall be mounted on the forklift in an easily accessible location. The fire extinguisher shall be a minimum 2-1/2 pound capacity ABC type, or equivalent. The fire extinguisher shall be UL299 listed and UL711 tested.

3.3.4.1 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard.

3.3.4.2 Foreign object damage (FOD). All loose metal parts, such as pins or connector covers, shall be securely attached to the forklift with wire ropes or chains. "Dog tag" style beaded chains shall not be provided. Removable panels, if provided, shall be attached with captive fasteners.

Tire valve stem caps shall be made of plastic.

3.3.4.3 Seatbelts and operator’s restraint.

3.3.4.3.1 Seat belt. An operator’s seat belt with a retractor shall be installed. The seat belt must conform to SAE J386, Type One. However, the installation of a lap belt alone will not be considered as adequate occupant restraint.

3.3.4.3.2 Additional restraint. Additional restraint devices designed to ensure the operator’s body remains entirely within the protection of the frame and overhead guard in the event of tip over will also be provided. The restraint system shall not interfere with operator access or mobility, or the vehicles operation. (That is special seat, shoulder belt, etc.)

3.3.4.3.3 Decal. A warning decal shall be provided advising of the hazards of tip over and the importance of using the restraint system.

3.3.4.4 Sound levels. The sound level measured at the operator’s station should not exceed 84 dB(A). If the sound level is above 84 dB(A), the contractor shall provide a hazardous noise warning plate stating that operator’s hearing protection is required when operating this forklift.

The plate shall be made of a corrosion resistant material and shall be at least 4.0 square inches.

It shall have black lettering on a yellow background and shall be located to be visible as the operator enters the cab, or is seated. Sound level shall not exceed 93 dB(A).

3.3.5 Electromagnetic interference (EMI). The forklift shall be in accordance with the following radiated emission and susceptibility requirements of MIL-STD-461: RE102 and RS103.

3.3.6 Human engineering. The forklift shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of arctic mittens and Mission-

Oriented Protective Posture (MOPP) Level 4 Chemical Warfare Gear.

3.3.7 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial components. Tapped threads shall have a minimum thread engagement in accordance with TABLE I.

TABLE I. Minimum thread engagement.

Material Minimum Thread Engagement

Steel 1.0 times the nominal fastener diameter

Cast iron, brass, or bronze 1.5 times the nominal fastener diameter

Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.3.8 Welders and welding. Welding procedures shall be in accordance with a nationally recognized welding code. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings.

3.3.9 Design. The forklift shall be designed for safe operation with the rated load capacity

(see 3.3.9.1) at all lift heights, fork tilt and fork positions that the forklift is capable of achieving.

The forklift shall be designed for a safety factor (based on material yield strength) of at least three times the test load (see 3.3.9.2).

3.3.9.1 Rated load. The rated load capacity for the Type I shall be 10,000 pounds at a horizontal and vertical load center of 48 inches. The rated load capacity for the Type II shall be 13,000 pounds at 54 inch horizontal load center, and 48 inch vertical load center.

3.3.9.2 Test load. The test load capacity for the Type I shall be 5,000 pounds at a horizontal and vertical load center of 48 inches. The test load capacity for the Type II shall be 6,500 pounds at

54 inch horizontal load center, and 48 inch vertical load center.

3.3.9.3 Load center. The horizontal load center is defined as the horizontal distance from the load carrying surface of the load backrest to the center of gravity of the load. The vertical load center is the vertical distance from the upper (load carrying) surfaces of the forks to the center of gravity of the load.

3.3.9.4 Fork spacing and side shift. The forks shall be capable of being adjusted laterally by hydraulic power, and meeting the requirements of 3.8.15. Rigid frame type forklifts only shall be capable of side shifting the forks by hydraulic power and meeting the requirements of 3.8.16.

3.3.9.5 Load backrest. A metal backrest shall be provided, either as an integral part of the fork carriage, or as a removable part thereof. The top of the backrest shall be 44 to 56 inches above the horizontal load carrying surfaces of the forks. The lowest portion of the backrest shall be from 1.0 to 10.0 inches above the top surfaces of the forks. Two ring type devices to restrain the load shall be located on the load backrest at 30.0 inches ±4.0 inches above the load carrying surfaces of the forks. The devices shall have a minimum inside diameter of 2.0 inches, and made of a material not more than 0.75 inches thick. The devices shall have a safety factor of at least 3 when a forward horizontal load, equal to the rated load, is equally applied to both devices.

Location of the devices shall not interfere with positioning the load against the backrest.

3.3.9.6 Fork back-guard. A removable fork back-guard shall be installed above the load backrest

(see 3.3.9.5) to prevent small containers from falling rearward off the forks. The guard shall not obstruct operator view. Its height shall be such that the total height of the load backrest and the fork back-guard shall be 80.0 to 82.0 inches when measured from the ground.

3.3.9.7 Instruments. In addition to the instruments supplied on the standard commercial forklift, an hour meter shall be installed in the instrument panel. When specified (see 6.2), the forklift shall be equipped with an inclinometer. All instruments, except the hour meter shall be lighted when the front floodlights (see 3.10.2) are illuminated.

3.3.9.8 Service brakes. Full air, air-over-hydraulic, or hydraulic-over-hydraulic type, foot controlled, all-wheel, service brakes shall be provided.

3.3.9.9 Parking brake. The parking brake actuation shall be independent from the service brakes.

The control shall be located within reach of the seated operator and in a position to permit easy and safe movement on and off the vehicle.

3.3.9.10 Steering. The forklift shall have power steering. In the event of a power failure the forklift shall be equipped with an emergency power steering mechanism (mechanical or electrical) conforming to SAE J1511. This supplement power steering mechanism shall allow the vehicle to be controlled while moving.

3.3.9.11 Load handling controls. All load motion controls shall be right hand operation and shall be of the self-centering type, i.e. controls shall return to the neutral position when released.

3.3.9.12 Cab. The forklift shall be equipped with an enclosed cab that shall incorporate the overhead protection requirements of ANSI/ITSDF B56.6-2005, and roll over protective structure

(ROPS) requirements of ISO 3471. There shall be a door on each side; or one door and one side, front, or rear window that meets the emergency exit requirements of SAE J185. There shall be at least two windows, one on each side, which can be opened for ventilation. The doors and windows shall be capable of securely locking in both the closed and open positions. A minimum clearance of 39 inches from seat to underside of cab, when measured in accordance with

ANSI/ITSDF B56.6-2005 shall be provided. The cab shall be equipped with an internal rear view mirror. When specified (see 6.2), the forklift shall be equipped with any of the following options. These options shall not interfere with the requirements in ANSI/ITSDF B56.6-2005:

a. Cab air conditioning

b. Rear window sunscreen

c. Front sun visor

d. external rear view mirrors

3.3.9.12.1 Removable cab. If the cab must be removed to meet air transportability requirements, a cab lifting device shall be provided. Any electrical connection that must be separated for cab removal shall be the quick-disconnect type. The cab lifting device shall be capable of being securely stored on the forklift when not in use. It shall be capable of lowering and raising the cab from the installed position to and from ground level.

3.3.9.12.2 Adjustable cab. If the vehicle is designed to operate with the cab in only one position, the ROPS/FOPS is only required in that position. If the vehicle is designed to operate with the cab in each discrete position, the ROPS/FOPS are required in each discrete position.

3.3.9.13 Heater and defroster. The heater and defroster normally provided on the contractor’s standard, commercial model shall be provided.

3.3.9.14 Towing hitch. A pintle type, towing hitch shall be installed at the center rear of the forklift, with the center of the hitch opening 22 to 30 inches above ground level. The pintle shall be capable of sustaining a rearward, horizontal force of at least three times the gross vehicle weight (GVW) of the forklift. The pintle type, towing hitch shall be designated as a retrieval device only, either by marking on the forklift or in the operator’s manual.

3.3.9.15 Towing lugs. Two lugs, one on each side of the towing hitch, used for towing or securing safety chains shall be installed. The lugs shall be of sufficient diameter to accept common chains and hooks three inches in diameter and capable of sustaining a rearward, horizontal force of at least three times the GVW of the forklift for a maximum of 500 feet.

3.3.9.16 Tires. The tires shall be pneumatic, with an off-road tread pattern. Tire loading shall not exceed the tire load limits specified in Tire and Rim Association Yearbook when using the off the road 5 MPH tables. When specified (see 6.2), the manufacturer shall provide a balanced wheel and tire assembly.

3.3.9.17 Horn. The manufacturer’s standard horn shall be provided.

3.3.9.18 Conveyorized fork attachment. The forklift shall be equipped with two conveyorized fork attachments (one for each fork) to be used for the transfer of a loaded 88 inch wide by 108 inch Air Force HCU-6E aluminum pallets; 10,000 pounds for Type I and 13,000 pounds for

Type II. The pallets shall be picked up with the 108 inch dimension lateral to the forks

(perpendicular to centerline of forklift). The following features shall be included:

a. Each conveyor shall securely attach to each fork and shall remain securely attached during all pallet loading and unloading operations.

b. Each conveyor shall have two rows of rollers (one row on each side of the fork tine).

c. The rollers shall be sized, located, and spaced so that the conveyor provides lateral and longitudinal support to the pallet described in (see 3.3.9.18), without pallet damage or excessive wear, during loading and unloading.

d. Each conveyor roller shall be of adequate diameter, width, and wall thickness to support the transfer of the loaded pallet specified in (see 3.3.9.18).

e. A quick attach/detach reversible, dual purpose “toe” shall be incorporated on the leading edge of each unit between the longitudinal rows of rollers. The one edge of the “toe”, when exposed for use, shall provide a nonmetallic bumper to prevent metal contact with the aircraft. The other edge of the “toe”, when exposed for use, shall provide a wedge, equipped with varying diameter rollers, to permit sliding of the conveyorized forks beneath a loaded pallet resting on the ground.

f. An area on the forklift shall be provided to store the conveyorized attachments.

3.3.9.19 Parking block. The forklift shall be equipped with the means of securing four parking blocks. The blocks should be easily accessible. The dimensions of each block are 5.50 X 7.50 X

20.00 inches (see Figure 3).

3.3.9.20 Air compressor. When specified (see 6.2), the forklift shall be equipped with an auxiliary air compressor equal to or better than the electrical air compressor from Gast

Manufacturing Co., Model 3HBB-19-M323 (see link listed below). The compressor shall be equipped with a universal air coupler.

http://www.gastmfg.com/pdf/piston/specsht/3h3l.pdf

3.3.9.21 NATO plug. The forklift shall be equipped with a NATO Plug equivalent to

NSN 5935-01-044-8382.

3.3.9.22 Crew protection kit (CPK). When specified (see 6.2), the Crew Protection Kit (CPK) conformance testing shall be completed. When specified (see 6.2), the manufacturer shall provide a field installed CPK in container. When specified (see 6.2), the manufacturer shall install the field installed CPK on the forklift prior to delivery.

3.3.9.22.1 CPK description. The CPK will provide protection against direct small arms fire and improvised explosive devices (IED). The CPK shall not only protect from the direct and indirect fire but also include protection from secondary projectiles. The CPK consists of all items that remain on the machine in all configurations, the part removed for transport configurations and any forklift modifications required to accept the armor package (e.g. armored floor panel, suspension and tire changes due to the increased weight of the armor kit, etc.). To facilitate the removal and installation of the CPK for transport configuration, electrical connections that must be separated for cab removal shall be the quick-disconnect type.

3.3.9.22.1.1 CPK armor. The armor CPK shall be easily installed and maximize commonality of attaching hardware with no special tools required for maintenance. Operator’s visibility shall not be impeded to the point of not being able to safely operate the forklift. The left hand door shall have a combat lock to provide security for the operator. Means shall be provided to prevent accidental closure when parked on an incline thereby reducing the risk of injury to personnel.

Operation of the egress shall be capable of being accomplished internally by the driver or externally by rescue personnel without tools. However, the use of a wrench to unlock the combat lock shall be the same combat rescue wrench use for the other armored vehicles (e.g.

HMMWV, Material Handling Equipment and Construction Equipment). The CPK shall be equipped with a heater, air conditioner, two exterior mirrors and rear camera.

3.3.9.22.1.2 CPK emergency egress. The CPK shall be equipped with a separate emergency egress. The emergency egress shall allow escape in the event that the cab door is inaccessible or inoperable. The emergency egress shall be operable from the interior without the use of tools.

An override shall be provided so that emergency personnel outside the cab can open the emergency egress. The override shall consist of square headed shafts that have 5/8-inch across http://www.gastmfg.com/pdf/piston/specsht/3h3l.pdf flats dimension, which when rotated from the outside, will allow the emergency egress to be opened. A roof emergency egress hatch shall provide a round opening of not less than 28" in diameter.

3.3.9.22.2 CPK armor EPA exemption. Pollution control technologies that are affected by the sulfur level of JP-8 fuel either in maintenance or life expectancy shall not be used, e.g., Exhaust

Gas Recirculation (EGR), NOx traps, catalytic converters, etc. The forklift is not subject to EPA nonroad emissions standards since the forklift contains permanent revisions for the application of

Armor. This determination is in accordance with 40CFR, sections 89.908 and 1068.225. The contractor shall ensure National Security Exemption labeling requirements are met in accordance with EPA regulations.

3.3.9.22.3 Forklift performance with CPK. Some degradation in machine performance is allowed when the CPK is installed. With the CPK installed, the "lateral stability travel" stability requirement of ANSI/ITSDF B56.6-2005 for fixed boom length forklifts is reduced. A side slope inclinometer indicating the reduced slope operational limit shall be installed inside the

CPK clearly visible to the operator. Some restrictions in visibility are acceptable. Rear visibility is improved with the installed rear camera system. When the CPK is installed, the forklift must meet the testing requirements of roll over protective structure (ROPS) per ISO 3471 but will not be certified to ISO 3471. If the machine exceeds 126 in height with the CPK installed, the actual height will be noted on the CPK data plate.

3.3.9.22.4 Removeable CPK. If the CPK must be removed to meet transportability requirements, and a separate lifting asset is required to raise or lower the optional CPK. The lifting asset shall be provided by the manufacturer with the CPK, and the lifting capacity shall be the noted on the

CPK data plate.

3.3.9.22.5 CPK transportation and storage. The CPK shall be delivered and stored in a container that is new, weatherproof, non-collapsible, lockable, repairable, and suitable for repeated use.

The container shall be configured such that all components of the armor kit are protected during shipment, and to facilitate quick inventory of the contents. When the armor kit is installed on the forklift, the container shall store all items removed from the forklift to facilitate armor installation. The container shall have forklift pockets that conform to STANAG 2828 that allow the container to be fork lifted from all four sides. The containers shall be capable of being transported by military and commercial vehicles, trailers, trains, marine vessels, aircraft, dolly sets and shall withstand the impact forces encountered in shipment without damage or permanent deformation. The containers shall be capable of being transported by C-130, C-5, and C-17 with or without supporting equipment existing in the DoD system. The container shall be painted the same color as the armor kit contained within.

3.3.9.22.6 CPK data plate. There shall be a separate permanently installed, corrosion resistant, metal plate that shows the center of gravity location in the air-transport mode and tie-down instructions for all aircraft pertaining to this specification (see 1.1). The following information shall also be on the plate:

Vehicle curb weight of machine with CPK (lbs)

Gross weight of Machine with CPK, max (lbs)

CPK Asset NSN Number

Machine height in operational mode

Lifting Capacity for CPK C-kit Removal

3.3.9.23 Aircraft loading fork attachment. The forklift shall be equipped with an aircraft loading fork attachment to be used for positioning fixed tongue, rolling stock of no more than 2 fixed axles, 2000 lbs tongue weight, and 10,000 lbs gross weight when measured with horizontal tongue.

3.3.9.23.1 Aircraft loading operations. Use of the aircraft loading attachment is limited to operations that support loading rolling stock into and out of cargo aircraft including but not limited to the C-5 and C-17. The aircraft loading ramp must be no steeper than the forward kneeled, aft ramp of the C-5 with a sufficient loading envelope to allow the forklift to enter the aircraft in operational mode, (see 3.6.1). Operations are limited to hard paved surfaces with level terrain with the forklift in first gear. The operator, without leaving his seat and while maintaining full control of the forklift, shall be able to see the pintle on the ALFA during all operations. The aircraft loading attachment shall be retained using MIL-DTL-25959 qualified tiedown adjusters and the associated MIL-DTL-6458 qualified chain connected to the aircraft loading fork attachment. The Aircraft Loading Fork Attachment must be removed to meet air-transport mode requirements (see 3.6.3.1). The aircraft loading fork attachment is not approved for any other operations. The following features shall be included:

a. Two steel D-ring devices with a minimum inside diameter of 2.0 inches and not more than 0.75 inches thick allowing secure retention on the forks / fork carriage and to remain securely attached to the forklift during all aircraft loading operations. The devices shall have a safety factor of at least 2 when the rated load is equally applied to both devices.

b. A pintle type, towing hitch shall be located at the center, end of the aircraft loading attachment opposite the fork insertion pockets.

c. The aircraft loading attachment shall be of adequate length, width, height and strength to support aircraft loading operations as specified (see 3.3.9.23.1)

d. Unless otherwise specified (see 6.2), the final paint (see 3.3.1.4) and markings

(see 3.3.2) shall be consistent with the colors of the forklift on which the aircraft loading attachment is attached. The top of the aircraft loading attachment shall have "10,000 LBS" stenciled in 1-1/2 inch high letters with paint.

e. Storage devices to allow the aircraft loading fork attachment to be stored on the forklift without modification to the forklift.

3.3.9.24 Non-slip coating. Floor plates and step surfaces shall be coated with a non-slip coating compound, or be furnished with a non-slip metal or tread plate surface.

3.3.9.25 Backup alarm. An audible backup alarm shall be furnished. The alarm shall automatically activate when the transmission selector is placed in reverse. The backup alarm must conform to SAE J994.

3.4 Environmental conditions.

3.4.1 Operating temperature range. The forklift shall be capable of operating in ambient temperatures ranging from -25° F to +125° F. When specified (see 6.2), the forklift shall be furnished with type A winterization and shall be capable of operating in ambient temperatures ranging from -65° F to +125° F.

3.4.2 Storage temperature range. The forklift shall be capable of being stored in ambient temperatures ranging from -25° F to +125° F. When specified (see 6.2), the forklift shall be furnished with type A winterization and shall be capable of being stored in ambient temperatures ranging from -65° F to +140° F.

3.4.3 Winterization. (Minimum Requirements).

3.4.3.1 Type C winterization. The forklift, at a minimum, shall be furnished with Type C winterization that shall protect to -25° F and shall consist of the following:

3.4.3.1.1 Starting aid. Glow plug(s) or a measure shot ether injection system shall be furnished.

3.4.3.1.2 Cab. The cab shall meet the requirements of (see 3.3.9.12), and shall also contain thermal insulation, if necessary, to meet the heating requirements of (see 3.4.3.1.3).

3.4.3.1.3 Cab heater and defroster. The heater shall have sufficient capacity to maintain a temperature of at least +40° F at cab floor level in an ambient temperature of -20° F.

3.4.3.1.4 Anti-freeze engine. To protect the engine from freezing, the coolant system shall be protected to -25° F with antifreeze.

3.4.3.2 Type A winterization. When specified (see 6.2), the forklift shall be furnished with Type

A winterization that shall protect to -65° F and shall consist of the following:

3.4.3.2.1 Power plant heaters. Engine coolant, engine oil and battery heaters shall be provided.

All heaters shall operate on either (110 volts @ 60 Hz) or (220 volts @ 50 Hz) alternating current. A three wire, 25 feet long weatherproof cable of adequate capacity for all heaters being used simultaneously shall be provided. The cable shall be able to connect to NATO and

American connectors. A stowage place shall be provided on the forklift to keep the cable when not in use. The heaters shall be as follows:

a. The coolant heater shall be installed in the engine block or lower coolant inlet hose.

A coolant circulating pump, driven by a 110 volt or 220 volt alternating current motor shall be provided when a coolant inlet hose heater is furnished. The heater shall have adequate capacity to maintain engine coolant at a temperature of 10° F in an ambient temperature of -65° F. It shall be controlled to limit engine coolant to not more than150° F.

b. An engine oil heater with adequate capacity to maintain engine oil at a temperature of at least +10° F in an ambient temperature of -65° F shall be furnished. It shall be controlled to limit engine oil temperature to not more than 150° F.

c. A battery heater shall be provided. It shall have adequate capacity to maintain battery electrolyte at a temperature of at least +10° F in an ambient temperature of -65° F, and shall have a thermostat to limit temperature of the electrolyte to not more than

+80° F.

3.4.3.2.2 Cab. The cab shall meet the requirements of (see 3.3.9.12), and shall also contain thermal insulation, if necessary, to meet the heating requirements of (see 3.4.3.2.3).

3.4.3.2.3 Heater and defroster. The heater shall be of sufficient capacity to maintain temperature of +40° F at cab floor level in an ambient temperature of -40° F.

3.4.3.2.4 Cold starting aid. A measured shot ether system or glow plug(s) shall be provided to assist in engine cold temperature starting.

3.4.3.2.5 Anti-freeze engine. To protect the engine from freezing, the coolant system shall be protected to -65° F with antifreeze.

3.4.4 Precipitation.

3.4.4.1 Rain. The forklift shall be capable of storage and operation during rainfall of 5-inches per hour for three consecutive hours and 10-inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with 6-inches of rain per hour impinging on the forklift at angles from vertical to 45°.

3.4.4.2 Snow. The forklift shall be capable of storage and operation during accretion of wet snow up to 2-inches per hour for at least 12 hours.

3.4.4.3 Ice. The forklift shall be capable of storage and operation with ice accretion up to 1.5-inches on exposed horizontal surfaces. An operator may use an ice scraper for five minutes during the start-up process.

3.4.5 Solar radiation. The forklift shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments.

3.4.6 Fungus. All materials used in the forklift shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The forklift shall be suitable for operation and storage in conditions encountered in a tropical environment.

3.4.7 Salt fog. The forklift shall be capable of storage and operation in high temperature, high humidity, salt laden, sea coast environments without damage or deterioration of performance.

3.4.8 Sand and dust. The forklift shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance.

3.5 Weight and dimensions.

3.5.1 Overall weight and dimensions. Overall forklift weight and dimensions shall not exceed:

Weight in air-transport mode 13,000 pounds on each axle.

Length, including forks 26.5 feet for Type I, 28.0 feet for Type II.

Width 102 inches.

Height in operational mode 126 inches.

Height in air-transport mode 102 inches.

3.5.2 Forks and fork carriage assembly. The forks and fork carriage shall have the following dimensions and restrictions:

Length of forks 72 ± 1 inches

Width of forks 8 inches (maximum)

Thickness of forks 2.5 inches maximum, except bend in forks heel may exceed 2.5 inches.

Fork tip thickness 0.5 inches (maximum)

Bottom taper of forks 30 inches (minimum), from tip of forks rearward

Fork carrier assembly width Shall be less than the overall width of the forklift

3.6 Transportability.

3.6.1 Operational mode. The operational mode shall be as the forklift is configured to meet the performance requirements of this document, including cab and counterweights.

3.6.2 Surface transportability. The forklift shall be transportable via all modes of surface shipment (highway, rail, and water) in accordance with MIL-STD-1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport, except that design for rail impact testing (see 5.2.5 of MIL-STD-1366) is not required.

3.6.3 Air transportability. The forklift shall be transportable on C-5, C-17, and C-130 aircraft.

Design criteria can be found in MIL-HDBK-1791. In all air transport configurations, the forklift shall be capable of being restrained and withstanding, without loss of serviceability, 2.0 G up and

4.5 G down accelerations, and shall be capable of being restrained and withstanding, without loss of structural integrity, 3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations. The forklift shall be equipped with pressure relief devices or configured for air transport to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure. The forklift shall drive on and off the aircraft, negotiating the required maximum ramp angles without shoring.

3.6.3.1 Air-transport mode. The air-transport mode shall be the fully operational forklift with only the following items removed, if necessary. To meet the air transportability requirements, refer to MIL-HDBK-1791 as a guide only:

a. Cab (see 3.3.9.12)

b. Conveyorized fork attachment (see 3.3.9.18)

c. Counterweight(s) (see 3.6.3.6)

d. Cab lifting device (see 3.3.9.12.1).

e. Operator’s seat may be removed or partially removed, but shall comply with requirements specified in (see 3.6.3.7)

f. Crew Protection Kit (see 3.3.9.22)

g. Aircraft loading fork attachment (see 3.3.9.23)

3.6.3.2 Shoring. The forklift shall be air transportable without shoring.

3.6.3.3 Axle weight. Axle weight shall not exceed 13,000 pounds.

3.6.3.4 Tire pressure. Tire pressure shall not exceed 100 pounds per square inch (psi) and shall not be reduced for air transport.

3.6.3.5 Conversion to and from air-transport mode. Conversion from operational to air-transport and from air-transport to operational mode shall take not more than 90 minutes each, using five people and only common hand tools (wrenches, screwdrivers, etc) with no damage to forklift or components. No other equipment or vehicle (cranes, other forklifts, etc) shall be required for the conversion to or from the air-transport mode. As a guide only refer to MIL-HDBK-1791.

3.6.3.6 Counterweight(s). If it is necessary to remove counterweight(s) to reduce the axle weights to 13,000 pounds, they shall be removed and installed by a furnished crane or hoist, and individual weights shall weigh not more than 900 pounds. Five men are the maximum number of personnel allowed to assist in the removal of the counterweight(s). Remember, safety should always be the top priority. An optional method shall be to remove and install the counterweights by a system on the forklift that uses its own power to lower and raise counterweight(s) to and from installed position, to and from ground level. In this case, the 900 pound maximum weight does not apply.

3.6.3.7 Operation in air-transport mode. The operator must be able to drive the forklift onto and off of all aircraft listed (see 1.1) for this specification. This will require that the operator be at, or below, the height specified in (see 3.5.1) and still be able to safely control the forklift.

3.6.4 Tiedowns. The forklift shall be symmetrically restrained during air and ground transport.

Tiedown points shall be rated at a minimum of 25,000 pounds, marked for capacity, marked as a

“TIEDOWN” in paint in the color specified in 3.3.2, with a clear opening compatible with

MIL-DTL-25959 tiedown devices. All tiedown points should be easily accessible and minimize the need to crawl under the vehicle when securing it. The tiedown points shall have a safety factor of 2.3, based on static load. Each end of each tiedown device shall terminate at a tiedown point and not pass through any other tiedown point. There shall be no interference between tiedown devices and the forklift. The tiedown provisions shall be in accordance with 4.1 through

4.12 of MIL-STD-209. There shall be a permanently installed, corrosion resistant, metal plate that shows the center of gravity location in the air-transport mode, and tie-down instructions for all aircraft pertaining to this specification (see 3.3.3.2). Refer to MIL-HDBK-1791 as a guide only.

3.6.5 Lifting provisions. The forklift shall be equipped with sufficient attachment points so located that it can be lifted by crane in its normal travel position. Each attachment point shall be marked "Lift Point" in painted letters in the color specified in 3.3.2. All lift points should be easily accessible and minimize the need to crawl under the vehicle when securing it. The lifting provisions shall be in accordance with 5.1 through 5.1.4 of MIL-STD-209.

3.7 Maintainability. The forklift shall be designed for maintainability in accordance with 5.9 through 5.9.18 of MIL-STD-1472; forces shall not exceed those specified for both males and females. The forklift shall be capable of being mechanically maintained by one person not to exceed 1 hour using common tools except where otherwise specified. The following items are provided as examples:

a. Remove, replace and adjust all engine-driven belts - 3/4 hour.

b. Remove and replace alternator - 3/4 hour.

c. Remove and replace all hydraulic system filters, screens, and strainers - 1 hour.

d. Remove and replace engine coolant system hoses - 1 hour.

e. Drain engine oil, remove and replace engine oil filter, and refill crankcase - 1/2 hour.

f. Remove and replace fuel filter elements - 1/2 hour.

g. Remove, replace and connect battery - 1/2 hour.

h. Drain transmission fluid, remove and replace all transmission filters and refill transmission in 1 hour.

i. Remove and replace starter - 1 hour.

j. Bleed and adjust brakes and refill master cylinder (if applicable), 2 men - 1 hour.

k. Remove and replace floodlights and taillight bulbs - 1/4 hour each bulb.

l. Lubricate all lubrication fittings with 2 strokes per fitting - 1 hour.

3.7.1 Servicing. The following items shall be easily accessible for inspection and servicing with the engine at operating temperature, without subjecting personnel to injury or burns. The items shall be in a covered area(s) that can be accessed (opened and closed) by one person without the need for tools:

a. Engine oil dipstick, oil filler, oil drain plug and fuel filter.

b. Transmission fluid level indicator and filler tube.

c. Radiator or engine coolant filler cap.

d. Hydraulic fluid reservoir level indicator and filler.

e. Battery for inspection, jumper cable attachment and removal.

f. Power steering reservoir (if provided).

3.7.2 Special tools. The design of the item shall minimize the requirement for special tools

(see 6.3.2). All special tools shall be provided with, and stored on, each forklift.

3.7.3 Diagnostic software. A copy of any diagnostic software required or recommended for maintaining the forklift shall be provided with each forklift on CD-ROM or DVD-ROM.

3.8 Performance.

3.8.1 Lifting speed. The forks with rated load shall be able to raise at a speed of not less than

40 feet per minute (fpm) over the entire distance from ground level to maximum lift height.

With the engine idling at engine manufacturer’s idle speed, the unloaded forks shall be able to raise at a speed of not less than 5 fpm over the entire lift range. Maximum fork lift speed for unloaded or rated load shall not exceed 60 fpm.

3.8.2 Lowering speed. The lowering speed of the forks with rated load shall be no less than 40 fpm (not to exceed 65 fpm). The lowering speed of the unloaded forks shall be no less than 20 fpm (not to exceed 65 fpm). The forks, either unloaded or with rated load, shall lower at a controlled rate, that is, no free-fall, uncontrolled operation, jerking, or condition which could cause damage to the lift system or forklift is permitted.

3.8.3 Travel speed. The travel speed with rated load shall be at least 15 miles per hour (mph) in forward direction, and not less than 9 mph in reverse.

3.8.4 Lift height. The lift height, with rated load on the forks and the forks horizontal, shall be not less than 75 inches when measured from ground to top surfaces of level forks.

3.8.5 Longitudinal slope operation. The forklift, with rated load, shall be capable of ascending and descending a 20% slope (11.3°) at a minimum of 2 mph when the load is in the uphill direction during both ascent and decent. It shall also be capable of accelerating upslope from a complete stop to at least 2 mph on a 20% slope (11.3°).

3.8.6 Lateral slope operation. With rated load on the forks, the forklift shall be capable of full circle operation, in both directions, at maximum steer angle, at a speed of not less than 2 mph, on a 15% slope (8.5°).

3.8.7 Drift. The lift assembly shall be capable of holding the rated load at maximum lift height for 60 minutes with not more than 0.5 inch of vertical drift, when the hydraulic fluid is initially at ambient temperature.

3.8.8 Turning radius. The maximum turning radius of the forklift, measured to outside of the tires, shall be 20 feet for the Type I, and 26 feet for the Type II.

3.8.9 Fork tilt. With no load on the forks, the minimum rearward tilt shall be 20°, and the minimum forward tilt shall be 10°. Tilting the forks from the maximum rearward tilt position to the horizontal position with rated load on the forks shall take at least 4 seconds.

3.8.10 Fork tine operation. As the forks are raised from the lowest position to maximum lift height, and lowered back to lowest position, the forks shall remain at their initial fork tilt

(±2°),with no change to the tilt control lever. The initial fork tilt can be any tilt that the forklift is capable of, not just horizontal. This applies to both forks, both empty and fully loaded.

3.8.11…