FirstArticleTestingRequirementsMJ1C.pdf

Testing Requirements for

MJ-1C

NSN 1730-01-491-1557

14 Nov 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 ensure conformance with Air Force specifications and standards with respect to workmanship, material, dimensions, and markings.

1.2. Environmental testing. The lift truck, with a 3000-lb load on the table shall be subjected to the following environmental tests in accordance with MIL-STD-810G (15 Apr 2014).

1.2.1. High Temperature Test, Method 501.6, Procedure II. The lift truck shall be operated at +125°F for 30 minutes.

1.2.2. Low Temperature Test, Method 502.6, 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 506.6, 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 510.6, 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 9,000 pound load on the table.

1.3.1. The forward frames shall be blocked to prevent transmission of the load through the tires. The rear of the lift truck shall be restrained to allow application of the full load. The lifting arms shall be set such that the top of the table is 30-50 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. Evidence of yield in any of the components which could in any manner prevent the lift truck from meeting operational requirements during service life shall be reason to consider that the lift truck has failed this test.

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 3000-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 arms shall be raised to a height of 75 inches, measured from the ground to the top of the table. It shall be lowered to a height of 6 3/8 inches from the ground.

1.4.1.1.2. Yaw. The table shall be rotated through a range of 360°±3° left and right of center.

1.4.1.1.3. Tilt. The table shall be tilted through a range of 5°+1°/-0° nose up and nose down from level.

1.4.1.1.4. Longitudinal. The table shall be moved through a range of 2 3/8±1/4 inches fore and aft of center.

1.4.1.1.5. Lateral. The table shall be moved through a range of 2 3/8±1/4 inches left and right of center.

1.4.1.2. Failsafe test. The table shall be raised off the ground. It shall be demonstrated by causing a hydraulic pressure loss to the lift cylinder counterbalance valve that the “failsafe” features of the main lift mechanisms are functioning.

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

1.4.1.4. 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.

1.4.1.5. 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.

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

1.4.1.6.1. Lift. The vertical drift, measured at the front of the table, shall not exceed ½ inch in one hour.

1.4.1.6.2. Tilt. The tilt drift of the manipulator head table, measured at the front or rear edge of the table, shall not exceed ½ inch in one hour.

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

1.4.1.6.4. Lateral. The lateral drift of the table, measured at the side of the table, shall not exceed ½ inch in one hour.

1.5. Mobility tests. The lift truck shall be subjected to the following mobility tests with a 3000-pound load on the table unless otherwise specified.

1.5.1. Towing test. With the lift truck powered down, unloaded and on a hard level surface, the lift truck shall be pushed 30 feet by two people without undue resistance of the drive train.

1.5.2. Road test. The lift truck shall be subjected to a road test of 150 miles over paved surface, 75 miles loaded and 75 miles unloaded. At the end of this test, the lift truck shall be examined for construction deficiencies such as loose bolts and nuts, broken welds, and yields. For periodic sampling tests, reduce toad test to 50 miles, 25 miles loaded and 25 miles unloaded. The temperature of the hydrostatic fluid shall be monitored and shall not exceed +210°F

1.5.3. Drive control test. It shall be demonstrated that the lift truck is capable of smoothly accelerating from a stop to 10 mph without evidence of “leaping” or “jumping.” It shall be demonstrated that, from 10 mph, the lift truck will come to a smooth controlled stop when the foot pedal is released. This test will be performed on a hard level surface.

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

1.5.5. Grade test. The loaded lift truck shall be stopped on a 10% slope. From this position the lift truck shall climb the slope a minimum of 15 feet. This test shall be repeated on a 20% slope with the lift truck unloaded.

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

1.5.7. Emergency braking test. With the lift truck loaded, simulate a power plant failure at 10 mph. It shall be demonstrated that the lift truck can be brought to a controlled stop using the hydraulic braking and steering systems.

1.5.8. Service brake test. The service brake shall hold the loaded lift truck on a 20% slope. In addition, the service brakes shall stop the fully loaded lift truck traveling at 8 mph on a hard level surface within a maximum distance of 16 feet.

1.5.9. Parking brake test. The parking brake shall hold the loaded lift truck on a 20% slope.

1.5.10. 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.

1.5.11. Power plant interlock. It shall be demonstrated that the lift truck will not power on without the directional control in “Neutral.”