PD08WRGBGBEA01.pdf

Support Equipment and Vehicle Management Directorate PD08WRGBGBEA01 Ground Support Equipment Branch Page 1 of 17 642 CBSSS/GBZO-ENF 11 Jan 08

CAGE 98752

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

FSC 1730

PURCHASE DESCRIPTION

UNIVERSAL MAINTENANCE STAND

1.0 SCOPE

This Purchase Description (PD) covers the requirements for the Universal Maintenance Stand (hereafter called UMS or the stand(s)). The UMS enables maintenance personnel access to multiple aircraft to complete a variety of maintenance tasks. The UMS shall be transportable and have the capability of being self-propelled, by both diesel engine and batteries, and be towed by a powered tow vehicle.

2.0 CLASSIFICATION

2.1 Documents

Government Documents: Copies of military standards are available from the Document Automation and Production Service, Building 4/D (DPM-DODSSP), 700 Robbins Avenue, Philadelphia, PA 19111-5094.

AFOSH STD 48-8 Controlling Exposures to Hazardous Materials

AFOSH STD 91-501 AF Occupational, Safety, and Health Standard

FED-STD-595 Colors Used in Government Procurement

MIL-STD-130M Identification Marking of U.S. Military Property

MIL-STD-810F Environmental Engineering Considerations and

Laboratory Tests

MIL-HDBK-1791 Designing For Internal Aerial Delivery In Fixed

Wing Aircraft

Other Documents: All other documents required by suppliers in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer.

OSHA 1910 Occupational, Safety, and Health Standards (Electronically available at:

http://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_to c_level=1&p_part_number=1910)

ANSI / SIA 92.6 Self-Propelled Elevating Work Platforms, American

National Standard for (Application for copies should be addressed to American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

PD08WRGBGBEA01 CAGE 98752

11 January 2008

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. FSC 1730

AWS D1.1 Structural Welding Code (Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126)

AWS D1.2 Structural Welding Code-Aluminum (Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126)

NFPA 70 National Electric Code (Application for copies should be addressed to National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471)

SAE AS8090 Mobility, Towed Aerospace Ground Equipment, General Requirements for, (Application for copies should be addressed to SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001)

2.2 Order of Precedence

In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supercedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 General

The UMS is utilized to allow access to aircraft to perform maintenance operations. The UMS shall be a self-propelled high lift platform per diesel engine and batteries. It shall utilize a hydraulically operated drive system and scissor lift platform with a minimum of a 2000 lb lifting capacity. The UMS platform will be a split deck design that may be split by separating the retracting panels.

3.2 Chassis/Frame

The chassis/frame of the UMS shall be a split deck four wheel design to effectively facilitate movement. The frame shall be constructed of corrosive resistant materials. The use of composite material whenever possible is acceptable to eliminate corrosion.

3.3 Maximum Footprint

The size and weight of the UMS shall be as small as practical, consistent with meeting the performance requirements specified in this document. The UMS shall be transportable by military cargo aircraft, spring-ride truck or trailer, rail car, and boat or ship. The UMS shall meet the ramp negotiation requirements specified in SAE AS8090 for Type 1, Class 2 equipment ground mobility. The footprint dimensions shall not exceed 201” long, 108” wide (with outriggers retracted) and 80” height. The UMS platform elevated working height is 36’.

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3.4 Weight

The weight of the UMS shall be evenly distributed to allow for ease of movement on rough terrain / flightline. The maximum weight, including normal fluid levels and maximum fuel load, shall not exceed 15,600 lbs.

3.5 Platform

Fall Protection: Fall protection system shall be provided on each platform as applicable per AFOSH 91-501 and OSHA 1910.66 Appendix C. Anchors, if required, shall conform to ANSI Z359.1 performance and design criteria.

Deck Surface: All decking surfaces shall be anti-skid and resistant to jet fuel, aircraft hydraulic fluid, and cleaning and degreasing solvents. Anti-skid surface shall prevent slipping and allow for kneeling, crouching, and lying down of maintainers without causing minor injuries such as abrasions during aircraft maintenance. Kick-plates shall be provided around perimeter of the stand in accordance with OSHA 1910.29 and AFOSH 91-501.

Handrails: Handrails / guard rails shall comply with all OSHA / AFOSH standards. The perimeter railing shall be operated by one person. All rails that can be removed shall have a locking mechanism (i.e. quick release pin, nut and bolts, fasteners) that will be engaged whenever the rails are in position.

Platform Access Opening: The platform access opening shall be used for the entry and exit of the platform from the access ladder / staircase. The platform access opening shall include a means of closing / blocking when personnel are on the platform. The system for closing / blocking the access opening shall not interfere with the platform working area.

3.6 Adjustable Deck Sections

Adjustable deck sections shall be a permanent part of the UMS and will extend and retract as required. If slides are utilized, a bearing support extension system shall be utilized. The adjustable deck sections shall be padded on the aircraft contact surface. Padding (bumpers) shall be easily replaceable. Each adjustable deck section shall be capable of being operated by one person without posing a tripping hazard. The force required to extend the adjustable deck section shall not exceed the requirements of MIL-STD-1472. Proximity sensors shall be utilized to help prevent damage to the aircraft.

3.7 Non-Corrosive Enclosure/Materials

The UMS material design is required to reduce the extensive man-hours and costs expended resolving corrosion-related issues (i.e. rust, fungus, mildew, pitting) with the objective to utilize composite materials to the maximum extent possible, without compromising structural integrity and reduction of the stand’s life expectancy. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion.

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3.8 Controls

Control Panel and Control Panel Door: The control panel shall have operating controls and gages on one control panel. Panel doors must cover the control panel and have visibility with easy access for users to monitor gages and operate switches. The panel door shall be closed to protect instruments from inclement weather along with weather stripping. Control Panel shall not be designed in such a manner as to allow access to control panel component adjustment by the users.

Step by step operating instructions for start-up/shutdown shall be mounted either on the control panel door or other suitable location close in proximity to the control panel for easy viewing by the operator. The control panel shall provide adequate weather protection for operational environment conditions.

Handheld Control: The UMS shall have operating controls on the platform. The controls shall be oriented and/or movable to allow the operator to be positioned in the necessary operational direction. The controls shall be protected against inadvertent activation and should automatically return to the neutral or off position when not activated. The control panel shall allow for overriding of the handheld controller. The handheld controller shall provide adequate weather protection for operational environment conditions.

Emergency Stop Device: The UMS shall be equipped with emergency stop devices located on the handheld controller and control panels.

Emergency Lowering: The UMS shall be equipped with a means to allow the emergency lowering of the platform.

3.9 Identification

Identification Plate: An identification plate, permanently marked, shall be securely attached to the UMS in a readily accessible location. The identification plate shall contain the following information:

• Nomenclature

• Manufacturer’s Part Number

• Serial Number

• Manufacturer’s name/cage code

• Date of Manufacture

• Contract Number

• National Stock Number

Six (6) blank lines shall be added after the above information for the purpose of etching future TCTOs.

Identification of product: Equipment, assemblies, and parts supplied in accordance with (IAW) this purchase description shall be marked per MIL-STD-

130. The Unique Identification (UID) which is described as a combination of data elements for an item that is globally unique and unambiguous, to ensure data integrity and data quality throughout life, and to support multi-faceted business

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3.10 Mobility

The UMS shall utilize wheeled outriggers that will allow the platform to be used in low speed travel operations while in the elevated configuration. The UMS shall conform to SAE AS8090 for a Type I, Class 2 vehicle and Towbar/Pintle Hook/Tie Down Rings. A towbar is required at the front of the UMS to provide a means of attaching a towing vehicle for movement of the UMS for flightline operations and mobility purposes. The towbar shall be capable of being securely stowed in a vertical position when not in use. The UMS shall be capable of being towed at speeds of up to 15 mph, with a 20 foot maximum safe turning radius.

Tie-down rings shall be installed to provide for security of UMS during shipment /lifting. Each tie-down point shall have a minimum clear opening of 1-1/2 inches.

UMS shall incorporate forklift tine guides and be capable of being transported by 10K 463L forklift. The UMS shall be capable of being configured for air shipment in less than 10 minutes and re-assembled to towing configuration in less than 5 minutes. The contractor should review MIL-HDBK-1791 for guidance on construction of the UMS to meet air transportability requirements for the KC-10, KC-135, C-130, C-17 and C-5 aircraft. Prior to preproduction approval, the contractor shall contact ASC/ENFC, 2530 Loop Road West, Wright-Patterson AFB, OH 45433-7101, 937-255-6039 to obtain certification of air transportability.

3.11 Fire Prevention, Safety, and Design & Construction Practices

The danger to personnel from fire and explosion shall be avoided by separation of hazardous substances from heat sources, suitable vents and drains and other fire prevention measures. All fastening devices and other parts which may cause hazardous conditions shall be secured or shall have other approved locking means applied. The use of safety wire as a securing method is not permitted.

The UMS shall conform to all applicable sections and paragraphs of OSHA

1910.29 and AFOSH 91-501 standards. The contractor shall be solely responsible for ensuring that the stands meet all applicable OSHA and AFOSH Standards as they apply to aircraft maintenance stands. The UMS shall successfully pass an OSHA and AFOSH inspection walk-down during the First Production Unit Testing. Failure to meet any applicable OSHA or AFOSH Standard, whether listed or unlisted in the contract documents, is a failure to meet the basic requirements of the contract.

3.12 Operational Environment

Operational Temperature Range: The UMS shall operate at temperatures ranging from -400F to +1300F. Oil Dilution and/or Ether to aid starting are not acceptable.

Storage Temperature Range: The UMS shall be capable of being stored at temperatures (non-operational) ranging from -650F to +1600F.

Operating Altitude: The UMS shall operate at altitudes ranging from sea level to

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. FSC 1730

7,000 feet above sea level. The UMS shall operate without malfunction after military air transport anywhere in the world.

Blowing Rain: The UMS shall withstand exposure equal to 40 miles per hour wind and rainfall rate of 2 to 5 inches per hour to meet anticipated worldwide deployment environmental conditions. The UMS(operating and non-operating) shall withstand exposure to rainfall at a rate of 1.4 in/hr with 35 mph winds during operation or storage without damage or degradation of performance. The UMS shall operate without damage or degradation of performance while sitting in water up to one (1) inch deep in its normal operating configuration and orientation.

Solar Radiation: The UMS shall withstand exposure equal to a hot dry cycle for 5 cycles.

Fungus (Tropical): The UMS shall withstand exposure equal to duration of 28 days in a tropical environment. All materials used on the UMS shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic, physical, or other properties sufficiently to remain entirely suitable for the purpose, and shall not present toxic hazards for personnel or have corrosive effects on adjacent materials. The period of affectivity of such treatment shall be at least equivalent to the service life of the part or component on which it is used.

Salt Laden Moisture (shipboard conditions salt and sea air): The UMS shall withstand exposure to salt air equal to 48 hours exposure time in both operating and non-operating conditions. The UMS shall be capable of sustained use and storage in high temperature, high humidity, and salt laden seacoast environments without damage or deterioration of performance.

Sand/Dust (Desert): The UMS shall withstand desert conditions equal to blowing sand, ambient temperature, 30% relative humidity and with heater operation in both operating and non-operating conditions. The UMS shall withstand exposure to 0.062 grams/cubic foot wind-blown sand (particle size 150-1000 microns) or dust (particle size less than 150 microns) at wind speeds up to 40 mph without damage and without deterioration in performance. Moving parts and electric circuits shall be protected against entry of sand and dust to the extent practical.

Items that are critically vulnerable to sand or dust shall have appropriate protection or inspection provisions. Finishes on exposed surfaces shall have sufficient hardness to have reasonable resistance to abrasions.

Snow Loads, Ice Accretion and De-Icing: The UMS shall withstand ice accretion up to two (2) inches per twelve (12) hours minimum. A suitably approved heater may be used to remove accumulated ice from critical areas thus permitting the unit to comply with the operating requirements.

3.13 Functional Characteristics

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Prime Movers: The UMS shall be powered and moved by either batteries charged by an electric motor or by a diesel engine. The ability to power the stand by either engine will allow the UMS to accomplish maintenance tasks within hangers that conform to a Class I, Division 2, and Group D environment.

Batteries: The batteries shall be of the commercial maintenance free type.

There shall be an appropriate number of batteries so the UMS is able to be driven and operated. The batteries shall have a dual power charging system: plug in receptacle and engine driven charging.

Electric Motor: The electrical motor shall be 115/220 V, 3 phase, 50/60

Hz. The engine shall be designed for use in group D atmospheres and class I, division 2 hazardous locations. The electric motor shall be designed, constructed, and installed in accordance with the National Electrical Manufacturers' Association Standards and pamphlet 70. The motor shall be capable of operating under all specified conditions without exceeding the nameplate rating. A fully charged stand shall be capable of 8 hours operation with a 25-percent duty cycle, or 2 hours of continuous operation.

Diesel Engine: The UMS shall be powered by a commercial diesel engine sized to meet all requirements specified herein, such as electrical power, the drive system, etc. The engine shall be compliant with all applicable EPA requirements for Tier 3 engines. The engine will be capable of running on JP-8 (primary) and diesel (secondary) fuels.

Drive System: The UMS shall have a drive system that shall utilize an automatic transmission. The speed of the stand, with the platform in the lowered position, shall not exceed 5 mph in the forward and reverse direction. The stand speed will not exceed 0.5 mph when the platform is elevated. Warning and directional indication shall be in accordance with SAE AIR1375, Minimum Safety Requirements for Special Purpose Airline Ground Support Equipment. The stand shall be capable of driving up and down a 1.5% slope.

Steering System: The UMS shall utilize commercially available driving controls / levers that are integrated into the handheld controller.

Electrical Components: The UMS shall utilize solid state components as much as possible.

Tires: The UMS shall utilize tires with split rims bolted in the middle. Pneumatic or foam filled tires capable of withstanding the weight of the stand with maximum load and capable of withstanding operations over rough improved surfaces (potholes), inclines, or hangar door tracks without causing damage to the tires.

Cargo Tie Downs: The UMS shall have cargo tie downs, each with a minimum operating load capability of twice the weight of the UMS.

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Towbar: The towbar shall have a lunette eye conforming to Specification A-A- 52464B. The towbar shall be attached to the frame of the UMS at two points to preclude “weaving” during towing operations. While driving or non-transport, the towbar shall be stowed in a vertical position, secured, and not hindering visibility.

Maximum Platform Load: The maximum platform load when fully elevated shall be no less than 2000 pounds.

Service Life: The UMS shall be designed to a minimum service life of 25 years.

3.14 Maintenance

Tools: Standard commercial tooling shall be utilized on the stand wherever possible to enhance maintainability, decrease maintainers’s cost, and reduce airlift requirements. In the event that standard commercial tooling cannot be used and specialized tooling is required, two (2) sets of special tool kits shall be provided for each stand. Metrics are not considered special tools. The UMS shall be field maintainable using minimal number of standard hand tools or other common equipment. All major components shall be replaceable by field level maintenance technicians. All inspections shall be capable of being performed from a standing position.

Test equipment shall be kept at a minimum, and if required, one (1) set shall be delivered to each location. The basic end-item contract shall provide the funding and acquisition strategy for the test equipment. Test equipment shall be available when hardware is purchased and delivered concurrently.

Operability: All components shall be selected and located for maximum ease of operation, servicing, inspections, and maintenance. All operator controls and equipment shall be centrally located in an easily accessible and readily available compartment. Switches and gauges at the operational position shall be located for good visibility and operation from a standing position. The instruments and controls compartment shall have a panel light and small door in which to protect the area during inclement weather. Additionally, the stand design shall allow the user to operate while wearing cold weather and or all Mission-Oriented Protective Posture (MOPP) gear.

Maintainability: Reducing the time required to access component parts for inspection maintenance enhances maintainability. The UMS shall be capable of being visually inspected and serviced without removing panels or components.

This shall include the incorporation of access doors or removable enclosures and modular design of sub-systems and components. Major components shall be removable by field personnel. Maximum use shall be made of quick disconnect connections to allow for rapid removal/replacement of component parts.

Enclosure/chassis material shall be field repairable. The maximum total downtime to perform all daily scheduled maintenance and servicing tasks shall be

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Maintenance Concept: Field Level repair shall support current Air Force support structure. The UMS design shall not require removal of other major components to access and replace failed subassemblies. The field shall be capable of repairing 80% of repairable parts.

Reliability: Reliability requirements shall be considered equal with cost, schedule, and other performance factors. Reliability shall remain a key consideration. The threshold Mean Time Between Preventative Maintenance (MTBPM) shall be 250 operating hours and not less than 500 cycles.

Preventative maintenance tasks shall be limited to a maximum of eight (8) man-hours. One cycle consists of driving the stand to specified location, implementation of a complete setup (including use of outriggers), and returning it to its original location.

3.15 Environmental Compliance

Hazardous Materials: The UMS design shall minimize the use of hazardous materials and protect the environment. The use of Ozone Depleting Chemicals (ODCs) and the hazardous materials established by the EPA listing are prohibited from use in any operation, maintenance, repair overhaul, and/or troubleshooting action required of the Government. The UMS shall meet the requirements of AFOSH STD 48-8 and all other applicable environmental, occupational safety and health standards. Personnel shall not be exposed to unsafe amounts of chemicals or other health and safety threatening agents in producing, using maintaining, storage, disposal, or servicing of the UMS or its components.

Noise Pollution: Noise levels generated by the unit shall be minimized by the use of sound reduction device features to preclude hearing damage to the operator and maintenance personnel. If the noise level generated exceeds 85 dba, the UMS shall be equipped with appropriate placards/markings to indicate that hearing protection is required.

3.16 Corrosion Prevention

Materials used in the construction/design of the housing, trailer, and major components of the UMS shall be corrosion resistant.

3.17 Media

Maximum use of exportable courses is required (i.e. DVD/VHS video, computer disc). Courses shall provided training on servicing, operational checks, theory of operation, adjustment procedures, troubleshooting, and associated diagrams. One

(1) set of courses shall be delivered to each location with production hardware.

3.18 Painted Color

The UMS paint shall comply with commercial standards and with FED-STD-595, semi-gloss gray, color 26173. The use of zinc rich primers shall be authorized.

Chemical Agent Resistant Coating (CARC) shall not be used.

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3.19 Welds and Welding

All welders shall be certified to weld in accordance with AWS D1.1, Structural Steel Welding Code or AWS D1.2, Structural Welding Code-Aluminum.

Certifications for all welders, being utilized on the UMS, shall be made available to the Government by the contractor. Welding procedures shall be in accordance with AWS D1.1 or AWS D1.2. All welding on the stand shall be completed in accordance with AWS D1.1 and AWS D1.2.

Any material other than the Grades of Steel approved for use and listed in AWS D1.1, or Grades of Aluminum approved for use and listed in AWS D1.2, shall be prohibited for use on any walking/working surface or structural member of the

UMS.

4.0 PRODUCT CONFORMANCE PROVISIONS

4.1 Certification

The contractor shall certify that the product offered meets the characteristics of this product description and that the product conforms to the producer’s own drawings, specifications, standards, and quality assurance practices and is the same product offered for sale in the commercial marketplace. The Government reserves the right to require proof of such conformance prior to first delivery and thereafter as otherwise provided for under the provisions of the contract.

4.2 Classification of Tests

The inspection and testing of the Universal Maintenance Stand (UMS) shall be classified as follows:

a. Preproduction testing……………………………………See 4.4

b. Acceptance testing………………………………………See 4.5

4.3 Test Conditions

4.3.1 Standard atmospheric conditions

Unless otherwise specified, all tests required by this document shall be conducted at an atmospheric pressure of 29.5 to 30 inches Hg, temperatures of 70o F + or – 5o F, and a relative humidity of 60 to 70 percent. When tests are conducted with atmospheric pressure, temperature, and/or humidity differing materially from the above values, proper allowance shall be made in gauges and instrumentation for the difference from the specified condition.

4.3.2 Preliminary run-in and calibration

Preliminary run-in of the UMS may be recommended by the manufacturer and shall be performed prior to submission of the unit for testing. A certified log of all preliminary running time, calibration date, etcetera, shall be submitted with the unit.

4.4 Preproduction Testing

4.4.1 Test Sample

One UMS shall be subjected to the tests specified in 4.6. The contractor shall provide a Test Plan for all test criteria, to this document, for the First Production Unit Testing. Preproduction tests may be waived upon the review and acceptance of a manufacturer’s certification.

4.4.2 Test Report

After completion of the Preproduction Unit tests, a Formal Test Report shall be provided by the contractor. The Test Report shall include all information and results from Section 4.0 of this document.

4.4.2.1 Reliability and Maintainability Information

The following information shall be included as an appendix to the test report:

a. All failures, servicing, adjustments, maintenance, and irregular functioning shall be identified by accumulated operating time, cycles, miles, or position in the test procedure, as appropriate. Test conditions at the time of the events identified shall be recorded.

b. A summary of the engineering analysis and of any tests conducted to determine assignable causes for any failure or irregular functioning.

c. A summary of the engineering analysis leading to any corrections made to design, construction, quality control, or other procedures, or leading to any corrections to be made or proposed to be made to production items. The summary shall also include an analysis of the predicted effectiveness of such corrections.

d. Clock time and person-hours required for each maintenance and servicing action taken during the tests. A brief description of the experience and qualifications of the personnel taking such actions.

e. Test activity or contractor comments on item features or requirements that, if modified, should improve the item.

f. Test activity or contractor comments on use of maintenance conditions to be avoided or cultivated to increase the reliability or useful life of the item.

g. Any of the above information that is already included in the test report body need not be repeated in the information required by the paragraph, but clear reference to the location of the data shall be included.

4.5 Acceptance Tests

The acceptance tests shall consist of the individual tests.

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4.5.1 Individual Tests

Each stand shall be subjected to the following tests:

a. Examination of Product…………………………………….4.6.1

b. System Tests………………………………………………..4.6.2

4.6 Test Methods

4.6.1 Examination of Product

The UMS shall be inspected to determine compliance with the requirements specified herein with respect to parts, tightness of fittings, screws, bolts, workmanship, finish, materials, color, marking, weight, dimensions, capacity, towbar attachment points, airlift winch points, foolproofness, safety, ease of operability, and identification and instruction plates.

4.6.1.1 Serviceability

The UMS shall be inspected and evaluated from the standpoint of ease of maintenance, servicing, operation, and safety.

4.6.2 System Tests

The electrical system and controls shall be tested as a complete system. Any failure resulting from these tests shall be cause for rejection.

4.6.2.1 Electrical System and Controls

The UMS engine(s) shall provide sufficient power to the unit to allow movement of the unit, lifting of platform, and proper operation of all electrical components, controls and instruments as outlined in this document.

4.6.3 Towing and Maneuverability Tests

The UMS shall be tested IAW SAE AS8090 for a Type I, Class 2 vehicle. The stand shall be tested at speeds up to 15 mph, with a 20 foot maximum safe turning radius. All components shall remain securely fastened in place and in an operable condition. The platform shall be maneuvered by one person. Any failure of these tests shall be cause for rejection.

4.6.4 Assembly and Disassembly for Air Shipment

The UMS shall be configured for air shipment in less than ten (10) minutes, and re-assembled to towing configuration in less than five (5) minutes. The stand shall be configured for maintenance work in less than fifteen (15) minutes. Any failure of these tests shall be cause for rejection.

4.6.5 Environmental Tests

The UMS shall be subjected to the following tests conducted IAW the specified procedures of MIL-STD-810F. Upon completion of each test, the unit shall be subjected to the system tests specified in 4.6.2. Failure of the unit to operate and meet the accuracies specified during or after each exposure, failure, of any item or assembly due to deterioration from exposures in these tests, or formation of any

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. FSC 1730 undesirable condition that cannot be remedied by routine maintenance shall be cause for rejection. Individual environmental tests may be waived upon the review and acceptance of a manufacturer’s certification, to be provided with the Test Plan.

4.6.5.1 Low Temperature Test

The UMS shall be subjected to low temperature storage at -65o F + or – 3o F IAW method 502.4, Procedure I. The temperature shall then be raised to -40o F + or – 3o F and stabilized. Upon completion of this test, the unit shall be subjected to the system tests specified in 4.6.2. Any failure of these tests shall be cause for rejection. The Low Temperature test may be waived upon the review and acceptance of a manufacturer’s certification

4.6.5.2 High Temperature Test

The UMS shall be subjected to steady-state high temperature storage at 160o F + or – 3o F IAW method 501.4, Procedure I. The temperature shall then be lowered to 120o F + or – 3o F and stabilized. The system tests specified in 4.6.2 shall then be conducted. All controls, instrumentation, et cetera shall perform satisfactorily and meet the specified requirements at the 120o F condition. Any failure of these tests shall be cause for rejection. The High Temperature test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.3 Salt Laden Moisture

The UMS shall be subjected to salt-fog IAW method 509.4 for 48 hours. The unit shall comply with the requirements specified in 3.11. Upon completion of this test, the unit shall be subjected to the system tests specified in 4.6.2. Any failure of these tests shall be cause for rejection. The Salt Laden Moisture test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.4 Fungus Resistance Test

The UMS or representative material samples shall be subjected to fungus IAW method 508.5. The unit shall comply with the requirements as specified in 3.11.

Any failure of these tests shall be cause for rejection. The Fungus Resistance test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.5 Rain Test

The UMS shall be subjected to rain IAW method 506.4 Procedure I and the requirements specified in 3.11. Upon completion of this test, the unit shall be subjected to the system tests specified in 4.6.2. Any failure of these tests shall be cause for rejection. The Rain test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.6 Dust Test

The UMS shall be subjected to dust IAW method 510.4, Procedure I. The unit shall comply with the requirements as specified in 3.11. Upon completion of this test, the unit shall be subjected to the system tests specified in 4.6.2. Any failure

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. FSC 1730 of these tests shall be cause for rejection. The Dust test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.7 Solar Radiation

The UMS shall be subjected to solar radiation IAW method 505.4, Procedure I.

The unit shall comply with the requirements specified in 3.11. Upon completion of this test, the unit shall be subjected to the system tests specified in 4.6.2. Any failure of these tests shall be cause for rejection. The Solar Radiation test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.8 Snow Load Testing and Ice Accretion Test

The UMS shall be subjected to snow and ice conditions IAW method 521.2. The unit shall comply with the requirements specified in 3.11. Upon completion of this test, the unit shall be subjected to the system tests specified in 4.6.2. Any failure of these tests shall be cause for rejection. The Snow Load and Ice Accretion test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.5.9 Altitude Test

The UMS shall be completely serviced and subjected to altitude testing IAW method 500.4, Procedures I and II. Procedure I shall subject the unit to conditions normally experienced at 40,000 ft above sea level and then allowed to return to ambient conditions. The system tests specified in 4.6.2 shall be conducted.

Procedure II shall subject the unit to conditions normally experienced at 7,000 ft above sea level and allowed to stabilize. The system tests specified in 4.6.2 shall then be conducted at this condition. Any failure of these tests shall be cause for rejection. The Altitude test may be waived upon the review and acceptance of a manufacturer’s certification.

4.6.6 Welds and Welding

All welds shall be inspected to ensure proper penetration and visually verified to be free from weld defects including but not limited to, cracks, undercut, and porosity. Inspection shall be completed by an AWS Certified Weld Inspector during and after the construction of the platform. Documentation of all inspections of the welds on the platform shall be provided to the Government.

The Government reserves the right to require verification inspection at any time during construction per AWS D1.1 Paragraph 6.1.2.2, 5.1.1 of AWS D1.2, and non-specified NDT other than visual per AWS D1.1 Paragraph 6.6.5. All welding documentation for subsequent production units shall be made available to the Government at any time during the life of the contract pursuant to AWS D1.1 and D1.2.

4.6.7 Rolling Force/Rolling Resistance Test

The UMS shall be moved from a resting position on a semi-smooth surface (paved surface) with a force no greater than 150 pounds. Any failure of these tests shall be cause for rejection.

4.6.8 Platform Load Test

The UMS platform shall be loaded to four (4) times its maximum load capacity.

Upon completion of this test, no deformation shall have occurred, and contractor shall proceed with testing in accordance with 4.6.2. Any failure of these tests shall be cause for rejection.

4.6.9 Noise Test

The UMS shall be tested to and shall comply with the requirements specified in

3.15. Any failure of these tests shall be cause for rejection.

4.6.10 Operational Test

The UMS shall be operationally inspected for 30-days after all other tests specified herein have been successfully performed. The operational inspection will be performed at Travis AFB, California and will begin the day following the delivery of the UMS. The inability of the UMS to satisfactorily allow for maintenance as outlined in this document, or maximum distances and tolerances greater than those outlined in this document, shall be cause for rejection.

4.6.11 Reliability Test

The UMS shall be tested to and shall comply with the requirements in Section

3.14. Any failure shall be cause for rejection.

5.0 DOCUMENTATION

5.1 Warranty and Service Information

The manufacturer shall include with each unit delivered a document indicating the warranty and service agreement provided and the telephone numbers, addresses, electronic mail addresses and the points of contact for warranty issues, technical assistance and routine and emergency service.

5.2 Packaging

The preservation, packing, labeling and marking shall be as specified in the contract or order and IAW the contractor’s standard commercial practice.

5.3 Installation and Operation

The manufacturer shall supply all manuals such as operating instructions, parts lists, diagrams, and any other data pertinent to the operation of the unit.

5.4 Program Management

The contractor shall appoint a single person to serve as the program manager for this program.

5.4.1 Program Management Review (PMR)

The contractor shall schedule, host, conduct, and support semi-annual PMRs.

5.4.2 Biweekly Teleconference

A biweekly teleconference (as required) shall be held by the contractor, WR- ALC, AMC Representative, and DCMA to discuss issues, actions, deliverables, and expenditure status. Problem areas shall be identified with proposed solutions and outcomes.

5.5 Technical Data

5.5.1 Engineering Calculations

The contractor shall complete all supporting engineering calculations for the design development and execution phases of this program in accordance with the requirements of this section. All supporting engineering calculations, both formal and informal, shall be provided to the Government. These calculations include, but are not limited to, load bearing calculations, static and dynamic stress analysis, finite element analysis, electrical load calculations, equipment sizing calculations, hydraulic calculations, and wire sizing calculations. All engineering calculations utilized for any portion of the design development of the stand shall be submitted to the government.

Structural calculations and analysis including load bearing calculations, static and dynamic stress analysis, and finite element analysis, electrical load calculations, and calculations for pressurized systems (pneumatic and hydraulic) shall be formal calculations with statements of purpose, methods, assumptions, analysis, and conclusions clearly defined and presented. All calculations associated with the design of the UMS shall be stamped by a registered PE in the respective engineering discipline for the portion of the design being developed. Structural engineering calculations shall be stamped by a registered Structural Engineer or a registered Mechanical Engineer, with an appropriate background; Electrical calculations shall be stamped by a registered Electrical Engineer; etcetera. All PEs shall have an active and current license throughout the entire design and production phases of this program.

5.5.2 Preliminary Design Review (PDR) and Critical Design Review (CDR)

The contractor shall present two formal design reviews: a Preliminary Design Review (PDR), review of the contractor’s anticipated designs, and a Critical Design Review (CDR), review of the contractor’s finalized designs.

5.5.3 Design Reviews

In addition to the formal PDR and CDR, the Contractor shall transmit all design documentation to the Government, including but not limited to, engineering drawings and calculations, at defined intervals during the design development phase of this program.

The Government reserves the right to view any and all design and production documentation at any time during the design development or design execution

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. FSC 1730

(production) phases of this program to ensure that the design being developed and/or implemented is feasible to produce the item on contract, and to ensure program progress is being made to the specified contract schedule.