FAT_Requirements_27Jan.pdf

First Article Testing Requirements for

MHU-83D/E

NSN 1730-01-446-2422

PR FD2060-14-30452

27 Jan 2014

1. Test methods and procedures. Upon completion of each test there shall be no evidence of structural or hydraulic failure.

1.1. Examination of product. Each lift truck shall be completely inspected to insure conformance with this specification and all applicable drawings with respect to workmanship, material, dimensions, weight, and markings.

1.2. Environmental testing. The lift truck, with a 7000-lb load on the table shall be subjected to the following environmental tests in accordance with MIL-STD-810G (31 Oct 2008).

1.2.1. High Temperature Test, Method 501.5, Procedure II. The lift truck shall be operated at +125°F for 30 minutes.

1.2.2. Low Temperature Test, Method 502.5, Procedure I. The storage temperature shall be -65°F. The lift truck shall be operated at -40°F for 30 minutes.

1.2.3. Rain Test, Method 506.5, Procedure I. The lift truck shall be operated the last 10 minutes of each of the four 30 minute rain cycles.

1.2.4. Sand and Dust Test, Method 510.5, Procedure I. The lift truck shall be operated for 30 minutes.

1.3. Structural overload tests. The lift truck shall be subjected to the following static load tests with a 14,000 pound load on the table.

1.3.1. The lifting boom shall be set such that the top of the table is 48 inches above the ground. The load shall be placed on the table and held in that position for three minutes. Upon removal of the load, the table shall not have dropped more than 1/2 inch. This test shall be repeated with the lifting boom set such that the top of the table is 96 inches above the ground.

1.4. Functional tests. The lift truck shall be subjected to the following functional tests.

1.4.1. The following tests shall be performed with a 7000-lb load on the table.

1.4.1.1. Range of motion. The full range of motion for the following shall be demonstrated as described below. The tests shall be performed with the lift truck on a flat, level surface.

1.4.1.1.1. Lift. The boom shall be raised to a height of 96 inches, measured from the ground to the top of the manipulator head table. It shall be lowered to allow the front wheels of the lift to be raised a minimum of 2 inches clear of the ground.

1.4.1.1.2. Azimuth. The boom shall be moved horizontally through a range of 20°±2° left and right of center.

1.4.1.1.3. Yaw. The manipulator head table shall be rotated through a range of 104°±3° left and right of center.

1.4.1.1.4. Roll. The manipulator head table shall be rolled through a range of 7°+1°/-0° nose up and nose down of level.

1.4.1.1.5. Tilt. The manipulator head table shall be tilted through a range of 5°+1°/-0° left and right of level.

1.4.1.1.6. Longitudinal. The manipulator head shall be moved through a range of 2±1/2 inches fore and aft of center.

1.4.1.1.7. Outriggers. The outriggers shall be moved through a range of 24 ½ inches to 94 inches, measured between the inside front wheels.

1.4.1.1.8. Wheelbase. The front wheels shall be moved to provide a wheelbase range of not less than 89 ¾ inches to not greater than 113 ¾ inches, in 12-inch increments.

1.4.1.2. Cycle test. The boom shall be raised and lowered through the maximum lift range for 1000 cycles. During this test it shall be demonstrated that, with the engine at operating speed, the lift rate is not less than an average of 14 feet per minute for a complete cycle.

1.4.1.3. Failsafe test. The table shall be raised off the ground. It shall be demonstrated by causing a hydraulic failure that the “failsafe” features of the main lift mechanisms are functioning.

1.4.1.4. Incremental control test. The lifting mechanism shall demonstrate an incremental control capability of not more than 1/8 inch through the vertical lift range.

1.4.1.5. Azimuth test. The lifting boom shall be moved horizontally through its maximum range for 250 cycles. It sha1l also be demonstrated once that there is an incremental control capability of not more than 1/8 inch through the horizontal range.

1.4.1.6. Manual lift rate test. The auxiliary hand pump shall demonstrate that the lift boom can be raised or lowered through its maximum range in five minutes.

1.4.1.7. Hydraulic filter test. The pressure differential between the inlet and outlet of the filter housing shall be checked to insure that the differential does not exceed 50 psi at 30 gpm oil flow at an oil temperature of 100°F.

1.4.1.8. Drift test. This test shall demonstrate that, with the engine at operating speed, actuator drift does not exceed the limits specified below.

1.4.1.8.1. Boom. The vertical and horizontal boom drift, measured at the front of the manipulator head, shall not exceed ½ inch in one hour.

1.4.1.8.2. Tilt. The tilt drift of the manipulator head table, measured at the side edge of the table, shall not exceed ½ inch in one hour.

1.4.1.8.3. Roll. The roll drift of the manipulator head table, measured at the front or rear edge of the table, shall not exceed ½ inch in one hour.

1.4.1.8.4. Yaw. The yaw drift of the manipulator head table, measured at the table, shall not exceed 3.5 degrees in one hour.

1.4.1.8.5. Longitudinal. The longitudinal drift of the manipulator head table, measured at the front or rear edge of the table, shall not exceed ½ inch in one hour.

1.4.2. Manipulator head cycle test. The following tests shall be performed with a 6000-lb load on the forks for 250 cycles.

1.4.2.1. Yaw test. The yaw mechanism on the manipulator head shall move (yaw) through the maximum yaw range.

1.4.2.2. Roll test. The roll cylinders on the manipulator head shall move (roll) through the maximum roll range. It shall be demonstrated by causing a hydraulic failure that the “failsafe” features of the roll mechanism are functioning.

1.4.2.3. Tilt test. The tilt cylinders on the manipulator head shall move (tilt) through the maximum tilt range.

1.4.3. Boom and outrigger cycle test. The following tests shall be performed with no load on the lift truck for 250 cycles.

1.4.3.1. Boom cycle test. The boom shall be raised and lowered through the maximum lift range. During this test it shall be demonstrated that, with the engine at operating speed, the lift rate is not less than an average of 14 feet/minute for a complete cycle.

1.4.3.2. Outrigger test. The outriggers shall be fully extended and retracted through the full range.

1.4.3.3. Front wheel adjustment test. The front wheels shall be extended and retracted through the full range.

1.5. Mobility tests. The lift truck shall be subjected to the following mobility tests with a 7000-pound load on the table unless otherwise specified.

1.5.1. Road test. The lift truck shall be driven 500 miles loaded and 100 miles unloaded.

The test shall include not less than 1000 stop and go cycles.

1.5.2. Heat Exchanger test. During the road test the transmission fluid shall not exceed 200°F.

1.5.3. Grade test. The loaded lift truck shall be stopped on a 10% slope. From this position the lift truck shall climb the slope. This test shall be repeated on a 20% slope with the lift truck unloaded.

1.5.4. Speed test. The lift truck, with the engine at operating speed, shall demonstrate a minimum speed of 8 mph loaded and 13 mph unloaded.

1.5.5. Service brake test. The service brake shall hold the loaded lift truck on a 10% slope. In addition, the service brakes shall stop the fully loaded lift truck traveling at 8 mph within a maximum distance of 16 feet.

1.5.6. Emergency brake test. The emergency brake shall hold the loaded lift truck on a 10% slope.

1.5.7. Steering test. The lift truck shall demonstrate a maximum turning radius of 20 feet. It shall also be demonstrated that no more than three turns of the steering wheel are required to turn from lock to lock.