MILPRF32080E.pdf

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Distribution Statement A. Approved for public release; distribution is unlimited.

MIL-PRF-32080E

27 March 2013

SUPERSEDING

MIL-PRF-32080D

22 March 2013

PERFORMANCE SPECIFICATION

TRUCK, AIRCRAFT FUELING-DEFUELING, 6,000 GALLON, A/S32R-11

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 specification covers the requirements for one type of aircraft refueling cargo tank truck capable of refueling and defueling military and commercial aircraft on Government installations worldwide. The aircraft refueling truck is compliant with all applicable Department of Transportation (DOT) regulations for transportation and is air transportable in C-130, C-17, and C-5 aircraft.

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.

NOT MEASUREMENT

SENSITIVE

https://assist.dla.mil/

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

FEDERAL STANDARDS

FED-STD-297 Rustproofing of Commercial (Nontactical) Vehicles FED-STD-595/14052 Green, Gloss FED-STD-595/24052 Green, Semi-gloss FED-STD-595/31136 Red, Flat or Lusterless FED-STD-595/33446 Tan FED-STD-595/37038 Black, Flat or Lusterless FED-STD-595/37875 White, Flat or Lusterless FED-STD-807 Trucks: Heavy Commercial, 6X4 and 6X6, 19,500 to

30,000 KG (43,000 to 66,000 pounds) Gross Vehicle Weight Rating (GVWR)

COMMERCIAL ITEM DESCRIPTIONS

A-A-393 Extinguisher, Fire, Dry Chemical (Hand Portable) A-A-50696 Reels, Static Discharge, Grounding, 50 and 75 Foot

Cable Lengths A-A-52557 Fuel Oil, Diesel; for Posts, Camps, and Stations A-A-52624 Antifreeze, Multi Engine Type A-A-59326 Coupling Halves, Quick Disconnect, Cam locking Type

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-A-8625 Anodic Coatings for Aluminum and Aluminum Alloys MIL-B-18013/1 Battery, Storage, Support Equipment MIL-DTL-25524 Turbine Fuel, Aviation, Thermally Stable MIL-A-25896 Adapter, Pressure Fuel Servicing, Nominal 2.5 Inch

Diameter MIL-DTL-25959 Tie Down, Tensioners, Cargo, Aircraft MIL-PRF-27260 Tie Down, Cargo, Aircraft, CGU-1/B MIL-PRF-52308 Filter-Coalescer Element, Fluid Pressure MIL-DTL-53030 Primer Coating, Epoxy, Water Based, Lead and

Chromate Free MIL-DTL-53039 Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resist MIL-DTL-83133 Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-

34), NATO F-35, and JP-8+100 (NATO F-37) MIL-DTL-83413/10 Connectors and Assemblies, Electrical, Aircraft

Grounding: Jumper Cable Assembly, Aircraft to Fuel Nozzle, Discharger, Electrostatic

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Identification Marking of U.S. Military Property 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-882E Standard Practice for System Safety MIL-STD-889 Dissimilar Metals MIL-STD-1366 Transportability Criteria MIL-STD-1472 Human Engineering

MIL-STD-1791

Designing for Internal Aerial Delivery in Fixed Wing Aircraft

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-470 Designing and Developing Maintainable Products and Systems

MIL-HDBK-781 Reliability test methods, plans, and environments for engineering development, qualification, and production

MIL-HDBK-1223 Nontactical Wheeled Vehicles Treatment, Painting, Identification Marking and Data Plate Standards

(Copies of these documents, except for MIL-STD-1791, are available online at https://assist.dla.mil/quicksearch or https://assist.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. A copy of MIL- HDBK-1791 can be obtained from the Procuring Contracting Officer (PCO) or requested by contacting Air Transportability Test Loading Agency (ATTLA) at 937-255-6296.)

https://assist.dla.mil/quicksearch https://assist.dla.mil/

FOREIGN SPECIFICATIONS

EURO-ASIAN COUNCIL FOR STANDARDIZATION, METROLOGY AND

CERTIFICATION

GOST 10227 Fuels for Jet Engines, Specifications

(Copies of these documents are available online at http://www.gost.ru/wps/portal/pages.en.Main, from the Leninsky prospect, 9, Moscow, V-49, GSP-1, 119991, Russian Federation or English translations are available from various specification and standards publication technical services)

UNITED KINGDOM MINISTRY OF DEFENSE

Standard 91-87 Turbine Fuel, Aviation, Kerosine Type: Containing Fuel System Icing Inhibitor NATO Code: F-34 Joint Service Designation: AVTUR/ FSII

Standard 91-91 Specification and Qualification Procedures for Aviation Jet Turbine Fuel, Aviation Kerosine Type, Jet A-1 NATO Code: F-35 Joint Service Designation: AVTUR

(Copies of these documents are available online at http://www.dstan.mod.uk or from the UK Defence Standardization Room 1138, Kentigern House, 65 Brown Street, Glasgow G2 8EX)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications 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.

DRAWINGS

MS24484 Adapter, Pressure Fuel Servicing, Nominal 2.5 Inch Diameter

LAWS AND REGULATIONS

Code of Federal Regulations (CFR)

49CFR172.302 General Marking Requirements for Bulk Packaging

49CFR393

49CFR178

Federal Motor Carrier Safety Regulations Specifications for Packagings

49CFR178.346 Material and Thickness of Material 29CFR1910 Labor, Section XVII Occupational Safety and Health

Administration (OSHA) Parts 1900-1999

Air Force Instruction (AFI)

AFI-32.7086 Hazardous Materials Management

Federal Acquisition Regulation (FAR)

FAR 23.404 Agency Affirmative Procurement Programs

National Institute of Standards and Technology (NIST)

HDBK44 Section 3.31/S.1.1.4-5 Advancement of Indicating and Recording Elements

(Copies of The Code of Federal Regulations (CFR) may be obtained at http://www.gpoaccess.gov/cfr/index.html or available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC, 20402.)

(Copies of FAR and DFARS may be obtained from the Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954. Electronic copies of the FAR may be obtained from https://www.acquisition.gov/far/ . Electronic copies of the DFARS may be obtained from http://www.acq.osd.mil/dpap/dars/dfars/index.htm .)

(Copies of Government documents required by the contractor in connection with this acquisition functions should be obtained from or as directed by the contracting activity.)

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 these documents are those cited in the solicitation or contract.

AMERICAN PETROLEUM INSTITUTE

API 579-1/ASME FFS-1 Fitness for Service API RP 2003 Protection Against Ignitions Arising out of Static, Lightning, and Stray Currents

(Copies of API specifications are available from the American Petroleum Institute, 1220 L Street, NW Washington, DC 20005-4070 1220 or at http://www.api.org ).

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D1655 Aviation Turbine Fuels ASTM D975 Oil, Diesel Fuel ASTM B241/B241M Aluminum and Aluminum-Alloy Seamless Pipe and

Seamless Extruded Tube

ASTM A312/A312M

ASTM D910

ASTM D4306

ASTM D 4057

Pipes, Stainless Steel, Seamless, Welded and Heavily Cold Worked Austenitic, Standard Specification for High Temperature and General Corrosive Service Gasolines, Aviation Aviation Fuel Sample Containers for Tests Affected by Trace Contamination

Practice for Manual Sampling of Petroleum and Petroleum http://www.gpoaccess.gov/cfr/index.html https://www.acquisition.gov/far/ http://www.acq.osd.mil/dpap/dars/dfars/index.htm http://www.api.org/

ASTM D 4177

ASTM D5001

ASTM D5006

ASTM D3241

ASTM D6615

ASTM D7467

ASTM D7566

Products Practice for Automatic Sampling of Petroleum and Petroleum Products.

Aviation Turbine Fuels by the Ball-on-Cylinder Lubricity Evaluator (BOCLE), Measurement of Lubricity of, Standard Test Method for Fuel System Icing Inhibitors (Ether Type) in Aviation Fuels, Measurement of Oxidation, Thermal, Stability of Aviation Turbine Fuels (JFTOT Procedure) Standard Specification for Jet B Wide-Cut Aviation Turbine Fuel Standard Specification for Diesel Fuel Oil, Biodiesel Blend (B6 to B20) Standard Specification for Aviation Turbine Fuel Containing Synthesized Hydrocarbons

(Copies of ASTM standards may be obtained from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959. Electronic copies of ASTM standards may be obtained from http://www.astm.org )

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code

Section VIII Rules for Construction of Pressure Vessels

(Copies are available from the American Society of Mechanical Engineers, United Engineering Center, 345 East 47th Street, New York, NY 10017 - Electronic copies may be obtained from http://www.asme.org)

AMERICAN WELDING SOCIETY (AWS)

D1.1/D1.1M Structural Welding Code–Steel D1.2/D1.2M Structural Welding Code–Aluminum

(Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami FL 33126. Electronic copies may be obtained from http://www.aws.org)

ENERGY INSTITUTE

EI 1529 Aviation Fueling Hose EI 1581 Specification and Qualification Procedures for Aviation

Jet Fuel Filter Separators EI 1584 Four-Inch Hydrant System Components and

Arrangements http://www.astm.org/ http://www.asme.org/ http://www.aws.org/

(Copies are available from the Energy Institute, 61 New Cavendish Street, London W1G 7AR, UK or at http://www.energyinst.org).

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 385 Tank Vehicles for Flammable and Combustible Liquids NFPA 407 Aircraft Fuel Servicing

(NFPA documents may be obtained at http://www.nfpa.org/index.asp or from NFPA, Batterymarch Park, Quincy MA 02269-9101.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J534 Lubrication Fittings SAE AMS 336 Silicone Rubber, Extreme Low Temperature Resistant 55

– 65 Duro For Sheeting & Extrusion SAE J682 Rear Wheel Splash and Stone Throw Protection SAE J695 Turning Ability and Off Tracking

SAE J1614

SAE J994

SAE J1099

SAE ARP 1247

Wiring Distribution Systems For Off-Road, Self-Propelled Work Machines Alarm-Backup-Electric-Laboratory Performance Testing Technical Report on Low Cycle Fatigue Properties Ferrous and Non-Ferrous of Materials General Requirements for Aerospace Ground Support Equipment, Motorized and Non-Motorized

SAE AMS 2175 Castings, Classification and Inspection of

(Application for copies should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale PA 15096.) Electronic copies may be obtained from http://www.sae.org/servlets/index

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 specific exemption has been obtained.

3. REQUIREMENTS

3.1 First production. When specified (see 6.2), one aircraft refueling truck shall be subjected to first production inspection in accordance with 4.2.

3.2 Aircraft refueling truck description. The aircraft refueling truck shall receive, transport, store, and pump turbine and jet fuels in accordance with ASTM D910, ASTM D1655, MIL-DTL-5624, MIL-DTL-25524, MIL-DTL-83133, GOST 10-227, Def Stan 91-91, Def Stan http://www.energyinst.org/ http://www.nfpa.org/index.asp http://www.sae.org/servlets/index

91-87, ASTM D6615, and ASTM D7566. The truck has a capacity of 6000 gallons and is capable of: (1) continuously issuing fuel to aircraft at volumetric flow rates (flow rates) up to 600 gallons per minute (gpm), (2) continuously bottom loading fuel into the cargo tank at flow rates up to 750 gpm, (3) continuously defueling aircraft at flow rates up to 300 gpm, and (4) receiving fuel from a Type III hydrant system in order to independently issue fuel to the aircraft at flow rates up to 600 gpm or issue fuel to the aircraft refueling cargo tank at rates up to and including a maximum of 700 gpm (self-contained design; see 3.13 ).

3.3 Design and construction. The aircraft refueling truck shall be designed and constructed in accordance with all applicable European Union (EU) requirements in order to have the “CE” marking affixed (see 3.3.3.1). The aircraft refueling truck shall be designed and constructed so that no parts will work loose in service. It shall be built to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. It shall be weatherproof and designed to prevent the intrusion of water and sand into critical operating components. The aircraft refueling truck shall be designed to optimize energy efficiency while minimizing engine fuel consumption. Unless otherwise specified, SAE ARP 1247 requirements for aerospace ground support equipment, as applicable to a refueling truck, shall apply.

3.3.1 Materials, protective coatings, and finish. All components which come into contact with fuel shall be compatible with all fuels in accordance with ASTM D910, ASTM D1655, MIL-DTL-5624, MIL-DTL-25524, MIL-DTL-83133, GOST 10-227, Def Stan 91-91, Def Stan 91-87, ASTM D6615, and ASTM D7566. Magnesium alloys, wood products, polyvinyl chloride (PVC), polyester, room temperature vulcanizing rubber (yielding acetic acid), or asbestos shall not be used in any component or assembly of this truck. Zinc coated metals, brass, bronze, or other copper bearing alloys shall not come in direct contact with fuel.

3.3.1.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.3.1.2 Green Procurement Program (GPP). GPP is a mandatory federal acquisition program that focuses on the purchase and use of environmentally preferable products and services. GPP requirements apply to all acquisitions using appropriated funds, including services and new requirements. FAR 23.404(b) applies and states the GPP requires 100 percent of Environmental Protection Agency designated product purchase that are included in the Comprehensive Procurement Guidelines list that contains recovered materials (see 6.3.1), unless the item cannot be acquired:

a. Competitively within a reasonable timeframe,

b. Meet appropriate performance standards, or

c. At a reasonable price.

The prime contractor is responsible for ensuring that all subcontractors comply with this requirement.

3.3.1.3 Metals. All materials in contact with the fuel and not specified elsewhere in this document shall be corrosion resistant and shall not be adversely affected by or affect the fuel.

All components and piping downstream of the filtration system shall be of aluminum or stainless steel. All aluminum components in direct contact with fuel, except the tank, shall be anodized or chemically conversion coated. Brass components shall be minimized but accepted in hose couplings/hose reducers and drain valves. Copper components will be minimized but accepted in drain lines that render the product as sump fuel. All other material in contact with the fuel shall be free of cadmium, copper, lead, or zinc. Non-metallic materials shall not affect or be adversely affected by the fuel under any operating conditions specified for the equipment.

3.3.1.4 Impregnation of castings. Aluminum castings may be impregnated to prevent weeping.

3.3.1.5 Elastomers. Elastomeric materials shall be certified compatible with all fuels specified herein.

3.3.1.6 Protective coatings. Cleaning, chemical treatments, painting, plating, and films shall be in accordance with best commercial practice. 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. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications.

3.3.1.7 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotively compatible abutting surfaces is acceptable. The use of dissimilar metals only when separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

3.3.1.8 Finish. The exterior finish color of the aircraft refueling truck shall be as specified in

3.3.1.8.1 using the manufacturer’s standard commercial paint system. The tank boarding ladder (see 3.12.6) shall not be painted. Driveline and cab components, which are not visible during normal operations with the cab door closed, may be their original color. The finish top coat shall extend into the door jambs and hood jambs to the extent that the OEM finish color cannot be seen through the gaps between the body panels when the doors and hood are closed.

3.3.1.8.1 Gloss green. Unless otherwise specified (see 6.2b), all exterior surfaces, except for the tank boarding ladder, all trim, and compartment interior surfaces shall be painted gloss green, color number 14052 of FED-STD-595. The chassis and running gear may be green or black.

3.3.1.8.2 Semi-gloss green. When specified (see 6.2b), all exterior surfaces, except for the tank boarding ladder, all trim, and compartment interior surfaces shall be painted semi-gloss green, color number 24052 of FED-STD-595. The chassis and running gear may be green or black.

Driveline and cab components, which are not visible during normal operations with the cab door closed, may be their original color.

3.3.1.8.3 Desert sand. When specified (see 6.2b), all exterior surfaces, including driveline components (see 6.3.8), except for the tank boarding ladder, all trim, and compartment interior surfaces shall be painted tan 686A, color 33446 of MIL-DTL-53039.

3.3.1.9 Fluid traps and faying surfaces. There shall be no fluid traps on the aircraft refueling truck. Faying surfaces of all structural joints, except welded joints, shall be sealed to preclude fluid intrusion.

3.3.1.9.1 Ventilation. Ventilation shall be sufficient to prevent moisture retention and buildup.

3.3.1.9.2 Drainage. Drain holes shall be provided to prevent collection or entrapment of water or other unwanted fluid in areas where exclusion is impractical. All designs shall include considerations for the prevention of water or fluid entrapment and ensure that drain holes are located to effect maximum drainage of accumulated fluids. The number and location of drain holes shall be sufficient to permit drainage of all fluids when the unit is in a 10 degree incline in any plane. The minimum size of the drain holes shall be 0.25 inch.

3.3.1.10 Rustproofing. The vehicle chassis and cab shall be rustproofed to a tropical level in accordance with FED-STD-297. Rustproofing shall not be applied to the first production unit until after approval of the test report.

3.3.2 Markings. The aircraft refueling truck shall be marked for the appropriate service using MIL-HDBK-1223 for guidance. Four DOT hazardous material labels, number 1863, shall be mounted on the vehicle, one on each side of the forward 1/3 of the cargo tank, one on the upper right hand corner of the rear of the tank, and one on the front bumper of the truck. The aircraft refueling truck shall also be marked in accordance with 49 CFR 172.302 and National Fire Protection Association (NFPA) 407. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130. Markings shall be vinyl decals and shall be 1-inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than ½-inch high.

Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of FED-STD- 595, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of FED- STD-595. Other markings shall be painted red, color number 31136 of FED-STD-595 for trucks painted gloss green; painted black, color number 37038 of FED-STD-595 for trucks painted semi-gloss green; and painted white, color number 37875 of FED-STD-595 for trucks painted desert sand. The center of gravity of the empty aircraft refueling truck shall be stenciled on the unit within 1.0 inch of the calculated center of gravity.

3.3.2.1 Flammable. “FLAMMABLE” 4 or 6-inch letters shall be located on each side and the rear of the aircraft refueling truck.

3.3.2.2 No smoking within 50 feet. “NO SMOKING WITHIN 50 FEET” 4 or 6-inch letters shall be located on each side and the rear of the aircraft refueling truck.

3.3.2.3 Cargo fire avoid water. “CARGO FIRE-AVOID WATER” 2-inch letters shall be located on each side and the rear of the aircraft refueling truck.

3.3.2.4 Jet fuel product. “JET FUEL PRODUCT” 4 or 6-inch letters shall be located on each side and the rear of the aircraft refueling truck.

3.3.2.5 Emergency tank shutoff. “EMERGENCY TANK SHUTOFF” shall be marked in 2-inch letters near each emergency tank shutoff (see 3.10.2.1).

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 aircraft refueling truck in a readily accessible location. The Aircraft refueling truck shall have a Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. The aircraft refueling truck UID shall be the Vehicle Identification Number (VIN) and shall be marked as both a bar code and human readable markings. The “CE” marking shall be affixed in accordance with EU requirements on or adjacent to the identification plate. The identification plate shall contain the following information:

a. Serial Number

b. Vehicle Registration Number

c. Date of Delivery

d. Make and Model

e. National Stock Number

f. Commercial and Government Entity (CAGE) Code

g. Contract Number

h. Date of Warranty Expiration

i. Cargo Tank Capacity (Gallons)

j. Vehicle Weight, Unloaded (Pounds)

k. Gross Vehicle Weight (Pounds)

l. Fuel Type

m. Engine oil viscosities for ambient temperatures ranging from -40° F to +125° F

3.3.3.2 Transportation data plate. A transportation data plate shall be securely attached to the aircraft refueling truck in a readily accessible location. The data plate shall include as a minimum the following information:

a. Side and rear silhouette views of the aircraft refueling truck.

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

c. Shipping weight.

d. Loading cubage.

e. Overall height, width, and length.

f. Front and rear axle loads.

g. Tie down information.

3.3.4 Safety.

3.3.4.1 System safety. The design of the aircraft refueling truck shall not contain any system safety (to include environment and occupational health) mishap risk categories greater than medium as defined in TABLE III and TABLE V of MIL-STD-882E.

3.3.4.2 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 moving 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.

3.3.4.3 Foreign object damage (FOD). All loose metal parts, such as pins or connector covers, shall be securely attached to the aircraft refueling truck 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.

3.3.4.4 Sound levels. The maximum A-weighted sound levels produced during pumping operations shall not exceed 84 dBA at the operator's location, in front of the operator control panel.

3.3.4.5 Electromagnetic interference (EMI). The aircraft refueling truck shall be in accordance with the following radiated emission and susceptibility requirements of MIL-STD-461: RE102 (to the limits of the FIGURE RE102-4, Navy Fixed & Air Force curve) and RS103 (to the levels of TABLE VII) for the following ranges:

30MHz – 1GHz at 10 Volt per metre (V/m)

1GHz – 18GHz at 50V/m

3.3.4.6 Electrostatic discharge. The design of the aircraft refueling truck shall preclude equipment damage due to electrostatic discharge (ESD), protect personnel from electrical shock due to static charging, and prevent ignition of explosive atmospheres due to sparking.

3.3.4.6.1 Bonding. All metal components shall be bonded in accordance with API RP 2003. A bonding braid, with less than 10 ohms resistance, shall be attached to all sump drain locations.

3.3.4.6.2 Prevention of static electricity. Fuel shall not spray or free fall into or out of the cargo tank during operation or servicing. Nonmetallic components shall be certified to a resistance of 10E+8 ohms/in² or less.

3.3.4.7 Design and hydrostatic pressure ratings. All pumping and bottom loading system components shall have a minimum design operating pressure rating as required to meet all requirements as specified in 3.8.2 or 150 psig, whichever is greater, and shall withstand a hydrostatic pressure of 1.5 times the minimum design operating pressure.

3.3.4.8 Hazardous Material. The design of the aircraft refueling truck shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials (including hexavalent chromium) and the generation of toxic or noxious gases. The aircraft refueling truck shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance or disposal. For the purposes of this requirement, the Class I ODS and controlled substances identified in Chapter 4 of AFI 32-7086 shall not be used in any system, component, or process.

3.3.5 Human engineering. The aircraft refueling truck 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. The range of control positions of any device shall not obstruct the range of control positions of another device.

3.3.6 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. All components connecting to the chassis frame rails shall be installed in accordance with standard commercial practice. 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

3.3.7 Welders and welding. All welders shall be certified to weld in accordance with AWS D1.1 and AWS D1.2 for structural components and ASME Boiler and Pressure Vessel Code Section IX for the cargo tank and filter vessel. The contractor shall make available to the Government certifications for all welders being utilized on the aircraft refueling truck. Welding procedures and all welding on the aircraft refueling truck shall be in accordance with AWS D1.1 and AWS D1.2 and ASME Boiler and Pressure Vessel Code Section IX, as applicable. 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.

3.3.8 Lubrication. Lubrication fittings shall be in accordance with SAE J534. Grease seals shall include pressure relief devices to prevent damage. Extended lubrication fittings may be used to enhance accessibility.

3.3.9 Foolproofness. Where improper installation of an item causes a malfunction, an asymmetric mounting system shall be provided, where practical, to ensure proper mounting of the item.

3.3.10 Service life. The aircraft refueling truck chassis and the refueling system components shall be selected for a design service life of not less than 15 years and verified by Finite Element Analysis (FEA) and strain gauge testing based on the strain-life fatigue analysis technique/approach. Design stress levels shall be attained by utilizing a design load that is based on dynamic loading with a safety factor of two. The dynamic load shall be the combination of load forces that the structure must support or resist in a static state with adjustments for shock loads and accelerations in all directions encountered during air or full-capacity ground transport and operations. At a minimum, the dynamic load shall be 1.6 times the full static load, including all refueling system components and full-capacity cargo tank. All data, assumptions, calculations and IGS files shall be provided to the Government upon analysis completion.

3.4 Environmental conditions.

3.4.1 Operation and storage temperature range. The aircraft refueling truck shall be capable of operation and storage in ambient temperatures ranging from -40° F to +125° F.

3.4.2 Humidity. The aircraft refueling truck shall be capable of storage and operation at relative humidity from 0 to 100 percent.

3.4.3 Fungus. All materials used in the aircraft refueling truck 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 aircraft refueling truck shall be suitable for operation and storage in conditions encountered in a tropical environment.

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

3.4.5 Sand and dust. The aircraft refueling truck 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. Overall weight and dimensions in air transport configuration shall not exceed:

a. Weight 30,000 pounds.

b. Length 460 inches.

c. Width 106 inches.

d. Height 102 inches.

The aircraft refueling truck air transport configuration is with the cargo tank and pumping system empty.

3.6 Transportability.

3.6.1 Surface transportability. The aircraft refueling truck shall be transportable via all modes of surface shipment (highway (see 6.3.3), 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.

3.6.2 Air transportability. The aircraft refueling truck, without a Hydrant Service (HS) Module (HSM) (see 3.13), shall be air transportable on C-130, C-17, and C-5 aircraft. Design criteria can be found in MIL-STD-1791. In all air transport configurations, the aircraft refueling truck 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 aircraft refueling truck 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 aircraft refueling truck shall drive on and off the aircraft, negotiating the required maximum ramp angles without shoring.

3.6.2.1 Shoring. The aircraft refueling truck shall be air transportable without shoring.

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

3.6.2.3 Tire pressure. Tire pressure shall not exceed 100 psig and shall not be reduced for air transport.

3.6.2.4 Tie downs. The aircraft refueling truck shall be symmetrically restrained during air and ground transport. Tie down points shall be rated at a minimum of 25,000 pounds, marked for capacity, with a clear opening compatible with MIL-DTL-25959 and MIL-PRF-27260 tie down devices. Each end of each tie down device shall terminate at a tie down point and not pass through any other tie down point. There shall be no interference between tie down devices and the aircraft refueling truck. The axles may be used as tie down points; however, no more than 50 percent of the restraint in any direction may be provided by the axles.

3.6.2.5 Equipment removal and reconfiguration. Preparation for air transport shall take no more than 15 minutes and restoration to operating configuration shall take no more than 15 minutes for two persons using common hand tools (see 6.3.6). All equipment removed shall be stored on the aircraft refueling truck; caps and plugs shall permit moving and storage in transport configuration.

3.7 Reliability and maintainability.

3.7.1 Reliability. The aircraft refueling truck shall have a mean time between failure (MTBF) of at least 100 hours measured at 90 percent one-sided confidence limit. Definitions of reliability terms shall be in accordance with A.3.

3.7.2 Maintainability. The aircraft refueling truck 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.

3.7.2.1 Preventive maintenance. The recommended routine preventive maintenance interval (PMI) shall be at least 400 operating hours. Preventive maintenance tasks, other than tasks required daily or before operation, shall not require more than 24 man-hours. This shall be calculated by: ∑

N i i T i

PMMHPMMH

where:

PMMHT is the total preventive maintenance man-hours, i is a multiple of the routine PMI (that is, i=1 for the routine PMI, i=2 for every other routine PMI, etc.), and

PMMHi is the preventive maintenance man-hours at the ith

PMI.

3.7.2.2 Corrective maintenance. The aircraft refueling truck shall have a mean time to repair (MTTR) of no greater than 2.0 hours measured at a 90 percent confidence level (10 percent consumer’s risk). MTTR shall be calculated in accordance with A.4.5.3.

3.7.2.3 Inspection and servicing provisions.

a. Four people shall be able to perform all daily inspection and service tasks within 15 minutes without the use of tools. Daily inspection and service tasks include, but are not limited to: inspecting for leaks; checking brakes, steering, horn, lights, engine, transmission, power take-off (PTO), and drive belts; adjusting lubricants, coolant, windshield washer fluid levels, and tire pressure; draining sump and air reservoir;

activation and deactivation of the deadman device; and completely unwinding hose and connecting to the bottom loader.

b. Common hand tools (see 6.3.6) shall be used to the maximum extent possible. Any peculiar hand tool (see 6.3.7), if required to service or repair any part of the fueling system or a sub-system, shall be provided with each truck.

c. Drain plugs and filters shall be directly accessible and oriented to have unimpeded drainage to a catch pan.

d. The aircraft refueling truck shall be designed with maximum usage of sealed lifetime lubrication bearings.

e. The aircraft refueling truck shall be designed so the correct oil and coolant levels can be checked while the unit is not running.

f. The aircraft refueling truck shall be designed so that there is no need to disconnect or remove components to gain access to other components.

g. All pneumatic lines and electrical harnesses shall be equipped with quick disconnect fittings.

The aircraft refueling truck shall have a one task time limit of four hours for removing and replacing any item in the fueling system, such as: filter elements, the PTO, the pump, a hose reel, or a fueling hose replacement.

3.7.2.4 Relative accessibility. Critical items that require rapid maintenance shall be most accessible. When relative criticality is not a factor, items that require the most frequent access shall be most accessible. High failure rate items shall be accessible for replacement without moving non-failed items.

3.7.2.5 Error-proof design. The design of the aircraft refueling truck shall incorporate error-proofing in equipment mounting, installing, interchanging, connecting, and operating.

a. Equipment shall include physical features (for example, supports, guides, size, or shape differences, fastener locations, and alignment pins) that prevent improper mounting. In the absence of physical features, equipment shall be labeled or coded to identify proper mounting and alignment.

b. Equipment that has the same form and function shall be interchangeable throughout a system and related systems. If equipment is not interchangeable functionally, it shall not be interchangeable physically.

c. Connectors serving the same or similar functions shall be designed to preclude mismating or misalignment.

d. Design, location, procedural guidance, and suitable warning labels shall be provided to prevent damage to equipment while it is being handled, installed, operated, or maintained.

3.7.2.6 Special Tools. The design of the aircraft refueling truck shall minimize the requirement for peculiar hand tools. (see 6.3.7).

3.7.2.7 Diagnostic software and test equipment. A copy of any commercially available diagnostic software recommended for maintaining the aircraft refueling truck shall be provided with each aircraft refueling truck on CD-ROM or DVD-ROM.

3.8 Performance.

3.8.1 Mobility.

3.8.1.1 Turning diameter. The aircraft refueling truck wall-to-wall turning diameter, as defined by SAE J695, shall not exceed 99 feet in either direction.

3.8.1.2 Gradeability. The fully loaded aircraft refueling truck shall be in accordance with the gradeability requirements of FED-STD-807.

3.8.1.3 Suspension articulation. The fully loaded aircraft refueling truck shall negotiate an eight inch high radius top berm, with 15 percent approach and departure angles (secondary containment barrier around a fill stand), in a straight pass as well as a minimum radius turn mid-way in either direction. There shall be no structural failure of any component, including permanent deformation, or evidence of impending failure. There shall be no interference between the aircraft refueling truck components or between the aircraft refueling truck, the ground, and all required obstacles, with the exception of normal contact by the tires.

3.8.1.4 Speed. The fully loaded aircraft refueling truck shall be capable of achieving speeds of 55 mph on level, paved highway, 40 mph over an unimproved road (see 6.3.4), and 15 mph over cobblestone road (see 6.3.5).

3.8.1.5 Roadability. The fully loaded aircraft refueling truck, including filter system and piping, shall be capable of being driven continuously over a combination of paved roads at a minimum average speed of 45 mph, graded gravel or unimproved roads at a minimum average speed of 25 mph, and cobblestone roads at a minimum average speed of 10 mph.

3.8.2 Pumping system. The pumping system shall be capable of performing the following functions and at no time shall fuel flow be allowed to backflow through the meter and filtration system. For all flow modes of operation, pressure and flow shall be stable at any operating condition specified herein.

a. In High Flow mode, issue a minimum of 5700 gallons of fuel to an aircraft from the cargo tank, through the filtration system, the meter, and the single-point hose and nozzle at flow rates of 600 gpm +0/– 25 gpm with nozzle back pressures over the range of 0 psig to the operator selected maximum nozzle backpressure ± 5 psig. In High Flow mode, the pumping system shall be designed such that flow rate is continuously monitored through an engine automated control system (EACS). The EACS shall (1) control the flow rate by varying the engine RPM, and (2) adjust the flow rate to prevent the single-point nozzle pressure from exceeding the operator selected maximum nozzle pressure setting. The pumping system shall be equipped with an operator selected dual nozzle pressure control system (PCS) and shall include: (1) a primary PCS with operator selectable settings of either 50 psig or 35 psig maximum single-point nozzle pressure, and (2) a secondary PCS with 55 psig maximum pressure.

b. In Low Flow mode, issue a minimum of 5700 gallons of fuel to an aircraft from the cargo tank, through the filtration system, the meter, and either the single-point nozzle or the overwing nozzle (see 3.10.13.2) at flow rates of 100 gpm +10/– 0 gpm with nozzle back pressures over the range of 0 psig to 50 ± 5 psig. In Low Flow mode, the pumping system shall be designed such that flow rate is continuously monitored through an engine automated control system (EACS). The EACS shall (1) control the flow rate by varying the engine RPM, and (2) adjust the flow rate to prevent the single-point or overwing nozzle pressure from exceeding 50 ± 5 psig.

c. In Defuel mode, with the fuel level height no greater than ten feet above the ground;

defuel fuel a minimum of 5700 gallons from an aircraft through the single-point nozzle and hose, through the filtration system, the meter, and into the cargo tank at a minimum flow rate of 175 gpm without the assistance of aircraft boost pumps and 300 ± 10 gpm with the assistance of aircraft boost pumps. The minimum obtainable flow rate shall be at least 15 gpm. An auxiliary throttle shall be used for controlling flow. The deadman control system (DCS) operations shall terminate, upon fuel contact with the primary tank-level sensor, thus terminating flow (see 3.12.7.4).

d. In Defuel mode, with the fuel level at least three feet below ground level, defuel through a 15 foot long, 1.5 inch pigtail hose connected to the single-point nozzle, through the filtration system, the meter, and into the cargo tank at flow rates of 50 gpm. The minimum obtainable flow rate shall be at least 10 gpm. An auxiliary throttle shall be used for controlling flow. The DCS operations shall terminate, upon fuel contact with the primary tank-level sensor, thus terminating flow (see 3.12.7.4).

e. In HS mode, receive fuel through the HSM (see 3.13), from a Type III hydrant system, in order to independently: (1) issue fuel to the aircraft or, (2) fill the aircraft refueler cargo tank. When issuing fuel to the aircraft, the truck engine shall be operating and in the High Flow mode, High Pressure setting. All fuel shall pass through the filtration system, the meter, and the single-point hose and nozzle, at maximum flow rate of 600 gpm with single-point nozzle back pressures over the range of 0 psig to 50 ± 5 psig. When filling the cargo tank, the truck engine shall be operating and at no time shall fuel pass through the pump, filtration system, or the meter. The HMS system shall control flow rates from 0 to a maximum of 700 gpm with a maximum hydrant inlet pressure of 130 psig when filling the cargo tank. The HSM shall not utilize the EACS for regulating the flow and pressure control system.

3.8.2.1 Closed pump discharge. The pump shall operate at the maximum rated pump speed, with the pump discharge side closed, for a minimum of 30 minutes without evidence of damage or overheating.

3.8.2.2 Dry pump operation. The pump shall operate dry at maximum pump speed for 10 minutes without evidence of damage or overheating.

3.9 Chassis and cab.

3.9.1 Chassis. The truck chassis shall be a standard commercial chassis in accordance with FED-STD-807 for a six by four chassis with a two door cab, Type 1, Class F, as modified to comply with the specific requirements herein. A rear air suspension system shall be provided.

The fully loaded aircraft refueling truck shall be towable from the front with or without the front tires off the ground. The driver side and passenger side mirrors shall be electronically adjustable from the driver position within the cab. Both driver and passenger side mirrors shall be large enough to provide a clear and distinct perspective of the entire length of the truck and rear bumper. The truck shall include backup lights and a backup alarm. The backup alarm shall meet the Type D (87 dBA) requirements of SAE J994. Unless provided as standard equipment on the commercial chassis, all lighting shall be LED.

3.9.2 Frame analysis. An analysis shall be provided to verify that the truck frame shall withstand factored imposed loads of operation under all of the conditions described herein. The frame, less crossmembers and reinforcements, shall have a resisting bending moment (RBM) of each rail of not less than

GVWWBlbsinRBM ××≥− 167.0)( where:

WB is the wheelbase in inches, and GVW is the gross vehicle weight in pounds-force at the area of maximum frame rail depth. Bending is assumed to occur about the flexural members strong-axis.

3.9.3 Axle analysis. An analysis shall be required to verify that the commercial load rating of each axle shall exceed the gross imposed load, measured at the ground.

3.9.4 Wheel loading. An analysis shall be required to verify that the wheel loading variation on any axle shall not exceed 2.5 percent of the total axle load, for either curb or gross load conditions. Gross load conditions shall include the fully optioned aircraft refueling truck weight, plus the tank, pump and piping systems full of JP-8 fuel, and a crew of two 250 pound operators.

3.9.5 Engine, fuels, and exhaust system. The truck engine shall provide the necessary power to meet the minimum performance requirements specified herein while utilizing the most efficient technological resources of minimizing fuel consumption. The truck engine shall be capable of operating on 1-D S15, 1-D S500, 1-D S5000, 2-D S15, 2-D S500, and 2-D S5000 diesel fuels in accordance with A-A-52557 and ASTM D 975, JP-5, JP-8, Bio Diesel blends up to 20% in accordance with ASTM D7467, TS-1 with US military additive package in accordance with GOST 10-227, Jet A-1 in accordance with Def Stan 91-91, Jet A-1 with US military additive package in accordance with Def Stan 91-87, Jet A and Jet A-1 in accordance with ASTM D1655, and aviation turbine fuel blends (i.e. FT, HRJ, etc) in accordance with ASTM D7566. An engine emergency shutoff valve, with reset capabilities, shall be provided in the engine air intake system, controlled by the emergency engine shutoff switch located on the operator control panel (see 3.10.8.1).

3.9.5.1 Engine starting system.

3.9.5.1.1 Starter. The engine shall be equipped with a 12-volt DC electric starter.

3.9.5.1.2 Engine starting aids. The engine shall start within 15 seconds cranking in any ambient temperature within the required operating range of the aircraft refueling truck. Installed glow plugs, fluid starting aids, and heat from the winterization system (see 3.9.11.3), as shown in Table II, may be used prior to and during the start period to facilitate engine starting under the following conditions:

TABLE II. Engine starting aids

Temperature Range

Starting Aids Permitted

40° F through 125 oF None 1° F through 39° F Glow plugs and fluid starting aids -40 o F through 0° F Glow plugs, fluid starting aids, and heat from the winterization system

3.9.5.2 Exhaust system. The truck muffler shall be mounted under and behind the front bumper, with a right side outlet pointing down and forward. No portion of the exhaust system shall extend behind the truck cab.

3.9.5.3 Engine and related equipment. The aircraft refueling truck shall be equipped with a diesel engine. The engine shall be certified to comply with the strictest Environmental

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