Attachment_6_-_PSPEC_Rear_Door.pdf

DISTRIBUTION STATEMENT A: Approved for public release.

Program-Unique Performance Specification

FOR

Cougar Rear Door Upgrade

VERSION 1.1

28 June 2013

Signatures are on file

VERSION HISTORY

REVISION DATE INITIATED

BY

CHANGED BY BRIEF

DESCRIPTION

OF CHANGES

APPROVED

BY

Ver 1.0 31 August 2012 Program Office N/A N/A See Signatures

Ver 1.1 14 February

Program Office Program Office Update See Signatures

Table of Contents

1 SCOPE

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

2.1.1 Specifications, Standards, and Handbooks

2.1.2 Other Government Documents, Drawings, and Publications

2.2 Non-Government Documents

2.3 TEST PROCEDURES

2.3.1 Documentation

2.4 DOCUMENTS SOURCE

2.5 ORDER OF PRECEDENCE

3 REQUIRMENTS AND VERIFICATION

3.1 GENERAL

3.1.1 Responsibility for Verifications

3.1.2 Engineering Development

3.2 METHODS OF VERIFICATION

GFE List ANNEX B- Load List

1 SCOPE

This program is a response to United States Marine Corps Mine Resistant Ambush Protected Vehicle Egress Modification UUNS and the result of government testing. This Performance Specification describes the technical performance requirements for the Cougar Rear Door Upgrade. The Cougar Rear Door Upgrade is required to increase egress capability of the Cougar CAT I/II A1/A2 vehicle system by wholly replacing the current rear doors and upgrading the rear steps. The Cougar Rear Door Upgrade will reduce the force required to operate the door in any circumstance, especially those hazardous scenarios that may render the door unable to be opened due to an excessive amount of force (rollovers, submersions). The Cougar Rear Door Upgrade will also optimize supplemental factors such as usability, reliability, availability, maintainability, and overall ballistic performance.

The Rear Door system (hereafter referred to as ‘the system’) will reduce the force to open the door(s) using a door assist and will include armored door(s), hinges, opaque armor, transparent armor, emergency egress attachment points, first responder receptacles, primary/service and secondary/combat locks, as well as rear steps. In addition to the system, the interior ballistic armor around the perimeter of the system shall be replaced with a material with multiple sources of supply.

2 APPLICABLE DOCUMENTS

The documents listed in this section are specified in sections 3 and 4 of this Performance Specification, or they are listed to provide additional guidance. While every effort has been made to ensure completeness of this list, document users are cautioned that all specified requirements documents cited in sections 3 and 4 of this Performance Specification must be met if specifically called out in the performance specification. Unless exempted by the Code of Federal Regulations (CFR), Title 49 Volume 5, §571.7(c), all Federal Motor Vehicle Safety Standards (FMVSS), Federal Motor Carrier Safety Regulations (FMCSR), Environmental Protection Agency (EPA), Federal, State, Municipal requirements, Military Specifications extracts from performance sections, Military Standards extracts from requirements sections, Published Commercial Item Descriptions, Society of Automotive Engineer (SAE) Standards, and American Society of Testing Materials (ASTM) Standards specified herein shall apply to this program.

2.1 GOVERNMENT DOCUMENTS

The following Government documents form a part of this specification to the extent specified herein.

2.1.1 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. Unless otherwise specified, documents shall be the issue current on the date of contract award.

FED-STD-595 Colors Used in Government Procurement

MIL-DTL-53039 Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

MIL-DTL-53072 CARC System Application Procedures and Quality Control Inspection

MIL-DTL-64159 Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant

MIL-STD-130 Identification and Marking of US Military Property

MIL-STD-209K Interface Standard for Lifting and Tie down Provisions

MIL-STD 461F Department of Defense Interface Standard: Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-464C Department of Defense Interface Standard: Electromagnetic Environmental Effects Requirements for Systems

MIL-STD-642 Identification Marking of Combat and Tactical Transport Vehicles

MIL-STD-810G Environmental Test Methods and Engineering Guidelines

MIL-STD-1472G Human Engineering

MIL-STD-882E Standard Practice for System Safety

MIL-STD-171 Finishing of Metal and Wood Surfaces

STANAG 478 Emergency Towing and Recovery Facilities for Tactical Land Vehicles

TM 4750-15/1 Painting and Registration Marking

The following Federal Motor Carrier Safety Administration Regulations (FMCSR) is the revision published in Code of Federal Regulations Title 49, Volume 4:

FMCSR 393.27 Wiring Specifications

FMCSR 393.28 Wiring to be protected

FMCSR 393.31 Overload Protective Devices

FMCSR 393.32 Detachable Electrical Connections

FMCSR 393.33 Wiring Installation

FMCSR 393.80 Rear Vision Mirrors

ATPD 2352R Purchase Description Transparent Armor

The following Federal Motor Vehicle Safety Standards (FMVSS) are the revision published in Code of Federal Regulations Title 49, Volume 5, Revision October 1, 2002:

FMVSS 101 Controls and Display

FMVSS 108 Lamps Reflective Devices and Associated Equipment

FMVSS 111 Rear View Mirrors

FMVSS 206 Doors Locks and Door Retention Components

FMVSS 302 Flammability

2.1.2 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.

EPA Clean Air Act, Title VI-Stratospheric Ozone Protection

MRAP SCG MRAP Security Classification Guide, 1 November 2010

2.2 Non-Government Documents

The following other Government documents, drawings, and publications of the exact revision level shown form a part of this document to the extent specified herein.

BSS 7239 Boeing Toxic Burn Gas Generation

IEC 60529 Degrees of protection provided by enclosures

SAE J336 Sound Level for Truck Cab Interior

SAE J680 Location and Operation of Instruments and Controls in Motor Truck Cabs

SAE J753 Maintenance Interval Chart

SAE J1292 Automobile, Truck, Truck-Tractor, Trailer and Motor Coach Wiring

SAE J1362 Graphical Symbols for Operator Controls and Displays on Off-Road Self Propelled Work Machines

SAE J1455 Joint SAE/TMC Recommended Environmental Practices for Electronic Equipment Design (Heavy Duty Trucks)

2.3 TEST PROCEDURES

2.3.1 Documentation

AEP-55 Vol 1 Ed.1 Procedures For Evaluating The Protection Level Of Logistic And Light Armoured Vehicles

ITOP-2-2-617 FR/GE/UK/US Vulnerability Testing of Combat Vehicles and their Components/Subsystems

TOP 2-2-620 Resistance Of Armored To Severe Shock TOP 2-2-710 Ballistic Test Of Armor Materials TOP 2-2-711 Ballistic Testing Of Armor Weldments TOP 2-2-715 Protection By Armored Vehicles Against Kinetic Energy Projectiles ITOP 2-2-716 Fr/Ge/Uk/Us Measurement Of Behind Armor Debris TOP 2-2-722 Fragment Penetration Test Of Armor ITOP 4-2-508 Vehicle Vulnerability Tests Using Mines TOP 4-2-840 Vehicle Vulnerability Tests Against Roadside Improvised Explosive Devices

2.4 DOCUMENTS SOURCE

Copies of military specifications, standards, handbooks, drawings, and publications can be obtained from the contracting activity or as directed by the contracting activity. Potential vendors and bidders are responsible for obtaining any and all documents referenced. Possible sources of other documents are listed below:

Department of Transportation (DOT) Federal Highway Administration Washington, DC 20591

Society of Automotive Engineers 400 Commonwealth Drive Warrendale, PA 15096

American Conference of Governmental Industrial Hygienists (ACGIH) 6500 Glenway Avenue Building D-7 Cincinnati, OH 45211

2.5 ORDER OF PRECEDENCE

In the event of a conflict between this Performance Specification and cited references, this Performance Specification shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. If there is a conflict between references, the Vendor is required to contact, in writing, the Cougar Program Office for clarification.

3 REQUIRMENTS AND VERIFICATION

Requirements specified in section 3 are defined as thresholds (T) unless noted as objectives (O).

3.1 GENERAL

3.1.1 Responsibility for Verifications

Unless otherwise specified in the contract, the Contractor is responsible for the acceptable performance of the end item in accordance with this specification. The Contractor may use their own facility or any other facility suitable for the verification requirements specified herein unless otherwise directed. The Cougar Program Office reserves the right to perform any of the verifications set forth in the specification where such verifications are deemed necessary to ensure supplies and services meet prescribed requirements.

3.1.2 Engineering Development

Testing shall be conducted by the Contractor to measure performance and disclose design problems in order to make corrections prior to final design of the engineering development system.

3.1.3 METHODS OF VERIFICATION

Methods of Verification are identified in the verification column in Section 3.

N/A. Not Applicable (title only, etc.) or not appropriate for testing.

Certification (C). Certifications are defined as Contractor-furnished documents certifying compliance with the specific requirement criteria. Certifications shall be signed by the Contractor’s certifying official or responsible party, and shall include all supporting performance, inspection, test, and analytical data, as applicable. As directed by the Cougar Program Office, certifications may be used in lieu of additional verification methods.

Certifications are subject to Cougar Program Office confirmation.

Inspection (I). Inspections constitute those activities conducted by the Cougar Program Office inspector for the purpose of evaluating vehicle/component attributes and characteristics against the requirements. Verification shall be accomplished by visual or physical examination of the end item or its subsystems/components, and may include but are not limited to recording measurements, evaluating physical characteristics and interfaces with respect to form, fit, and function, and reviewing descriptive documentation.

Test (T). Testing shall be conducted by the Cougar Program Office or Contractor, and shall be accomplished through the systematic physical operation of the system, its subsystems or components, under appropriate and specified conditions, with or without instrumentation, and the collection, analysis, and evaluation of resulting data.

Analysis (A). Analyses shall be conducted by the Cougar Program Office or Contractor and shall consist of technical or mathematical evaluations, mathematical models, simulations, algorithms, charts, diagrams, representative data, or other appropriate means to demonstrate compliance with the Section 3 requirement.

Demonstration (D). Demonstration is performed by the Cougar Program Office where the performance of operations at the system/sub-system level where visual observations is the primary means of verification.

Demonstration is used when quantitative assurance is not required for verification of the requirement.

Requirements specified in section 3.2 are defined as thresholds (T) unless noted as objectives (O).

ID Requirements Method Verification Narrative

3.2 Design Characteristics

3.2.1 The system shall be interchangeable for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

D The government will perform fit checks to verify the system is interchangeable for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

3.2.2 The system shall be common for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

I

The vendor will provide detailed design reviews and the government will inspect and take measurements to verify the system is common for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

3.2.3 The system shall be compatible with all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

D The government will perform fit checks to verify the system is compatible for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

3.2.4 The system shall accommodate all service-specific Government Furnished Equipment (GFE) as specified in Annex A.

I, D The government will inspect and demonstrate operation of all GFE to verify the system accommodates all GFE and the vendor successfully relocated the systems

3.2.5 When the door(s) is fully open, it shall not obstruct more than 3% of the projected overall dimensions of the hull cutout (O)

I The government will measure the obstruction of door opening to verify the system does not obstruct the overall dimensions of the hull cutout

3.2.6 The rear door upgrade shall standardize the rear door cutout for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles.

I The government will inspect the system to verify rear door cutout is standard for all CAT I/CAT II A1/A2, Ambulance and TOW vehicles

3.2.7 The interior ballistic armor around the perimeter of the system shall be replaced.

I The government will inspect the ballistic armor to verify it has been replaced

3.2.8 The system and surrounding interior ballistic armor interfacing with the door shall not use or require a flexible spall blanket.

I The government will inspect the system to verify compliance

3.2.9 The system shall not degrade current towing capabilities to include but not limited to trailers, like-vehicle towing, and recovery operations (T)

D, T The government will perform tow testing to verify compliance with the requirement

3.2.10 The system’s door(s) shall fully open/close and allow egress while trailer is attached or during like-vehicle towing.

D The government will demonstrate the door opening/closing to verify compliance with the requirement

3.2.11 System shall include a door stop to prevent door over-travel when the door assist is disengaged. I, D

The government will inspect and demonstrate the door to verify compliance with the requirement

3.3 Overall System Survivability

3.3.1 The system shall not separate from the vehicle during 2.6X Underbody IED (UBIED) blast events, (T), ‘4x’ UBIED blast event (O)

A/T

The Cougar Program Office will perform 2.6X Net Explosive Weight (NEW) full-scale underbody/under wheel blast testing and simulations against complete vehicle systems to gain insights into the vulnerability of the total system including crew.

3.3.2 No part of the system shall become a secondary projectile in the occupant compartment during 2.6x UBIED event (T), ‘4x’ UBIED event (O)

A/T

The Cougar Program Office will perform 2.6X NEW full-scale underbody/under wheel blast testing and simulations against complete vehicle systems to gain insights into the vulnerability of the total system including crew.

3.3.3 The system shall not degrade the ballistic (Small arms, RPG, etc) protection of the Cougar FoV as defined in MPB. (T)

A/T

With the threats listed in the MPB, the Contractor shall provide analysis and or certifications and the Cougar Program Office will perform ballistics tests or run simulations of ballistics threats to verify the requirement (ITOP 2-2-713).

3.3.4 The system shall meet the ballistic (small arms, RPG, etc) protection defined in CPD 1.1 (O)

T With the threats listed in the CPD 1.1, the Cougar Program Office will perform ballistics tests or run simulations of ballistics threats to verify the requirement (ITOP 2-2-713).

3.3.5 The system shall be functional, excluding the steps, after any event defined in MPB (T), 2.6X UBIED event (T), ‘4x’ UBIED threat (O)

T

With the UBIED events, the Cougar Program Office will perform 2.6x and 4x NEW full-scale underbody blast testing and simulations against complete vehicle systems to gain insights into the vulnerability of the total system including crew. (ITOP 4-2-508).

3.3.6 The system shall not separate, excluding the steps, from the vehicle during or after any 360 degree rollover event (T)

T The Cougar Program Office will perform a 360 degree rollover test or simulation to verify the requirement.

3.3.7 Installation of the system shall not degrade existing armor, i.e.

drilling, welding or cutting and heat effected zones (T)

A/C/T The Contractor shall provide analysis and or certifications, and the Cougar Program Office will perform ballistic tests to verify the armor performance is not degraded (ITOP 4-2-508).

3.3.8 The rear door system shall not inadvertently open during or after a 2.6X UBIED event (T), ‘4x’ UBIED event (O)

T The Cougar Program Office will perform 2.6X and 4X NEW underbody/under wheel blast tests and verify the door does not inadvertently open during or after the event.

3.3.9 The system shall operate (open) in still water at 4m depth while system is submerged following water submersion for 30min (T)

T The Cougar program office will perform submersion tests to verify the egress capability is still functional during a submersion event

3.3.10

Any attachments shall be integrated in such a manner as to not degrade existing internal or external armor properties (i.e.

Internal Ballistic Package Module (IBPM), etc) and maintain (T) or increase (O) current armor coverage

A/I/T The Contractor shall provide analysis and or certifications, and the Cougar Program Office will perform ballistic tests to verify the armor performance is not degraded (ITOP 4-2-508).

3.4 Force Protection

3.4.1

The system shall not introduce injuries to any occupant as defined by current ATD IARVs (Anthropomorphic Test Device Injury Assessment Reference Values) when subjected to 2.6X UB IED events (T)

A/T

The Cougar Program Office will perform 2.6x NEW underbody/under wheel blast tests and simulations against complete vehicle systems to gain insights into the vulnerability of the total system including crew and verify occupants do not exceed current IARVs. (ITOP 4-2-508).

3.4.2

The system shall not introduce injuries to any occupant as defined by current ATD IARVs (Anthropomorphic Test Device Injury Assessment Reference Values) when subjected to ‘4x’ UBIED blast events (O)

T

The Cougar Program Office will perform 4x NEW underbody/under wheel blast tests and simulations against complete vehicle systems to gain insights into the vulnerability of the total system including crew and verify occupants do not exceed current IARVs. (ITOP 4-2-508).

3.4.3 If the system provides any surface that could be used as an armrest, the component’s surface shall be padded

I The government will verify that padding is included if the system provides an armrest feature.

3.5 HSI

3.5.1 Abrasive coatings on surfaces shall be included for areas that will be used for walking or climbing in accordance with 5.9.4.8 (b.) of MIL-STD-1472G

I The government will inspect the system to verify compliance with MIL-STD-1472G

3.5.2

The system shall adhere to applicable sections for labeling and signs in accordance with MIL-STD-1472G 5.4, 5.6.4.6, and 4.2) to include but not limited to activate/de-activate points, handles, switches, manual releases or other control points.

I The government will inspect the system to verify compliance with MIL-STD-1472G

3.5.3 The system shall adhere to applicable sections for warning labels and placards in accordance with MIL-STD-1472G (5.7.2.1 and 4.2) for components that present hazards to personnel.

I The government will inspect the system to verify compliance with MIL-STD-1472G

3.5.4 The system shall not degrade existing rear field of view (T) T, A The government will measure the field to verify compliance with the requirement

3.5.5 The system shall improve rear field of view (O) T, A

The government will measure the field to verify compliance with the requirement

3.5.6 The system shall have no sharp edges, or burrs and all edges shall be rounded in accordance with sections 5.7.7.6 and

5.7.9.2.3 of MIL-STD-1472G

I The government will inspect the system to identify any potential hazards to verify compliance with MIL-STD-1472G

3.5.7

The interior of the door(s) shall be designed such that user interfaces can be located, accessed, and activated by 5th percentile female to 95th percentile male while wearing protective gear (MOPP IV, ballistic protection and gloved hands) in accordance with the applicable sections for Ground vehicles (5.6.1), Physical accommodation (5.8) and Anthropometric design (5.8.4) of MIL-STD-1472G

I, A, D The government will inspect and perform HFE testing on the system to verify compliance with MIL-STD-1472G

3.5.8

The system shall accommodate ingress/egress of 95th males with full combat IBA, ACH and MOLLE gear in accordance with the Anthropometric design (5.8.4) and Physical accommodation section (5.8) of MIL-STD-1472G.

D,I, T The government will inspect the system and perform HFE testing to verify the door opening is compliant with MIL-STD- 1472G

3.5.9

Interior dimensions and clearances of the seated occupant as defined to table XXX and applicable sections of 5.6.2.1 from MIL-STD-1472G shall not degrade from the current Cougar FoV measurements(T)

I, A The vendor will provide detailed design reviews and analysis and the government will inspect the system to verify it is complaint with MIL-STD-1472G

3.5.10 Interior dimensions and clearances of the seated occupant shall adhere to table XXX and applicable sections of 5.6.2.1 from

MIL-STD-1472G (O)

I, A The vendor will provide detailed design reviews and analysis and the government will inspect the system to verify it is complaint with MIL-STD-1472G

3.5.11

The system shall address litter loading/unloading in requisite combat equipment for Cougar Ambulance variants in accordance with Physical accommodations sections (5.8) of

MIL-STD-1472G

D, I, T The government will inspect the system and perform HFE testing to verify the door opening is compliant with MIL-STD- 1472G

3.5.12

Force, resistance, push, pull and strength limits shall follow the applicable sections of MIL-STD-1472G for the specific design chosen (e.g. handle, lever, or control) with the exception of the first responder receptacles torque below

A, D The vendor will provide detailed design reviews and analysis and the government will operate the system to verify compliance with MIL-STD-1472G

3.5.13 The system shall include glow-in-the-dark material (NSN 9390- 01-568-1116) on or around all internal handles.

I The government will inspect the system to verify compliance with the specification

3.6 Door Assist

3.6.1

The system's door assist shall be able to operate 1 cycle while the vehicle is upright on ground with a 5% (1:20) crown while the vehicle is shut down, disabled, or the vehicles power supply is depleted for 1 week (1 cycle = open and close)

D The government will operate and test the system's draw to verify the system is running on its independent power source

3.6.2

The systems door assist shall be able to perform 20 cycles (1 cycle = open and close) independent of vehicle power while the vehicle is upright on ground with a 5% (1:20) crown at 12 hours after vehicle power interruption (T)

D The government will operate and test the system's draw to verify the system is running on its independent power source

3.6.3

The systems door assist shall be able to perform 30 cycles (1 cycle = open and close) independent of vehicle power while the vehicle is upright on ground with a 5% (1:20) crown at 12 hours after vehicle power interruption (O)

D The government will test the system to verify it can perform the number of necessary cycles independent of vehicle power

3.6.4

The system’s door assist shall be able to perform 2 cycles (1 cycle = open and close) independent of vehicle power in any vehicle orientation except when the vehicle is resting on that plane of egress at 12 hours after vehicle power interruption (T)

D The government will test the system to verify it can perform the number of necessary cycles independent of vehicle power

3.6.5

The system’s door assist shall be able to perform 5 cycles (1 cycle = open and close) independent of vehicle power in any vehicle orientation except when the vehicle is resting on that plane of egress at 12 hours after vehicle power interruption. (O)

D The government will test the system to verify it can perform the number of necessary cycles independent of vehicle power

3.6.6 The system's door assist shall prevent crush injuries by detecting objects in door's inherent pinch points along the door periphery while closing. (O)

I/D The government will operate the system to demonstrate the object detection function and identify any potential hazards.

3.6.7 If a crush sensor is included, when a crush hazard is detected by the system, the door(s) will open 5 to 10 degrees to prevent injury or damage (O)

T The government will test the system to verify

3.6.8 The system's door assist and all of its components shall be internal to the door and/or vehicle (O)

I The vendor will present detailed design reviews and the government will inspect the system to verify the mechanism are internal to the vehicle or door

3.6.9 The system's door assist shall be activated by the same operator interface as the primary/service lock

D The government will operate the door to verify the controls work as required

3.6.10 The system's door assist shall have 2 actuation options:

automatic full open and operator defined partial opening (e.g.

automatic windows in a automobile)

D The government will operate the door to verify the controls work as required

3.6.11

The system's door assist shall hold the door in the position that the operator dictates until further input is given in any vehicle position for at least 1 hour (T) 4 hours (O) with no more than 10% change in opening angle. After 1 hour (T) 4 hours (O) degradation shall not allow the system to open or close faster than 18 deg per minute without operator input

T The government will operate the door to verify the requirement.

3.6.12 The system's door assist shall have interior and exterior manual releases located near the rear door(s) to disengage the door assist to allow for manual door operation.

I, D The government will inspect and demonstrate to verify compliance with the requirement

3.6.13 The system's door assist shall not create additional force to open/close the door when disengaged (O)

T The government will measure the systems pull force to verify compliance with the requirement

3.6.14

The system's door assist interior manual release shall be guarded from inadvertent release, accessible and operable within 3 seconds by the operator while wearing protective gear (MOPP IV, ballistic protection and gloved hands) IAW MIL-STD- 1472G

T, D

The government will perform HFE testing to verify the manual release is accessible and operable. The government will perform HFE testing to verify the location of the interior manual release

3.6.15

The system's door assist exterior manual release shall be accessible and operable within 3 seconds by 95th percentile males and 50th percentile female (T), 5th percentile female (O) as defined in MIL-STD-1472G while the vehicle is upright and the operator is standing on ground with a 5% (1:20) crown (plane of the 4 wheels)

D, T The government will perform HFE testing to verify the location of the exterior manual release

3.6.16 The system's door assist exterior manual release shall be guarded from inadvertent release

I The government will inspect the system to verify the requirement

3.6.17

The system’s door assist user interfaces shall be designed such that they prevent accidental actuation and do not impede use in accordance with section 5.1.1.8 of MIL-STD-1472G for prevention of accidental actuation (option a. recommended)

A, I, D The vendor will provide detailed design reviews and analysis and the government will operate and inspect the system to verify it is complaint with MIL-STD-1472G

3.6.18

The system’s door assist shall have remote activation control to open and close the door(s), accessible by the driver and a-driver while belted in the seated position while wearing protective gear (MOPP IV, ballistic protection and gloved hands) IAW MIL-STD-1472G

D, I, T The government will inspect and perform HFE testing to verify compliance with the requirement

3.6.19

The driver/a-driver’s door assist remote activation control shall remotely engaged/disengage the primary/service and secondary/combat locks and open/close door using a single action

D The government will operate the door to verify the controls work as required

3.6.20 The system’s door assist shall fully open/close the rear door(s) between 3 to 5 seconds while the vehicle is upright on ground with a 5% (1:20) crown

T The government will operate the door to verify the controls work as required

3.6.21 The system’s door assist shall fully open the rear door system in under 8 seconds while the vehicle is in any orientation except when the vehicle is resting on that plane of egress

T The government will perform testing to verify

3.6.22 The system’s door assist shall close the rear door between 3 and 8 seconds while the vehicle is in any orientation.

T The government will perform testing to verify

3.6.23 The door shall be capable of being padlocked (NSN 5340-00- 158-3805) from the exterior of the vehicle

I, D The government will inspect and operate the door to verify

3.6.24 Padlock shall mechanically inhibit external activation of the door assist.

I, D The government will inspect and operate the door to verify

3.6.25 Each door assist at each egress point shall operate independently such that failure of one door assist shall not degrade the function of any other door assist.

D The government will operate the door to verify it performs desired function

3.6.26 System shall withstand operating against a blocked door for 2 minutes without damage to system components or without causing a hazard.

A, D, I The vendor will provided analysis, and the government will measure the system and verify compliance with the requirement

3.6.27 System will provide the driver and A-driver a visual indicator of system activation throughout entire time system is activated and/or when the door is open.

I, D The government will inspect and operate the door to verify

3.7 Emergency Egress Attachment Points

3.7.1 The emergency egress attachment point(s) shall be located on the exterior of the rear door(s)

D The government will inspect the system to verify compliance with the requirement

3.7.2

The emergency egress attachment points shall be capable of overcoming primary/service lock and any door assist when used to externally open the door pulling within a 120 degree cone perpendicular to the rear door(s) with less than 10,000 lbs. (T)

T The vendor will provide test or analysis results and the government will test to verify the capability of the attachment points

3.7.3

The system's attachment points shall be capable of overcoming primary/service lock, any door assist and secondary/combat locks when used to externally open the door pulling within a 120 degree cone perpendicular to the rear door(s) with less than 10,000 lbs. (O)

C, T The vendor will provide test or analysis results and the government will test to verify the capability of the attachment points

3.7.4

The system's attachment points shall be capable of accepting a 1-1/2 inch pin as found on common service specific clevises on winches and recovery vehicles as defined in STANAG 4478 and

MIL-STD-209K

D, T The government will operate the system and test to verify the capability of the attachment points

3.7.5 The system's attachment points shall be labeled to indicate intended use as defined in MIL-STD-1472G

I The government will inspect to verify compliance with the requirement

3.8 First Responder Receptacles

3.8.1 The first responder mechanism shall open the secondary/combat lock from the exterior of the vehicle

D The government will operate the system to verify compliance with the requirement

3.8.2 The first responder receptacles shall be operable with Cougar adapter on the MRAP Universal Combat Lock Tool (UCLT) NSN:

2540-01-574-0491

D The government will operate the system to verify compliance with the requirement

3.8.3 The first responder operation shall have 2 positions, fully engaged and fully disengaged (over center or toggle)

D The government will operate the system to verify compliance with the requirement

3.8.4

The torque required to disengage the system's first responder shall not be less than 45 ft-lbs or more than 60 ft-lbs (T) resistance in any vehicle orientation. NOTE: The 'not less than' torques it set to prevent inadvertent opening due to multi-directional inertial loading during overmatch events. Since this first responder mechanism will override the primary and secondary latches, prohibiting inadvertent opening is critical.

T The government will operate the system to verify the force requirement to operate the system

3.8.5

The system's first responder shall be positioned at a height accessible by 50th percentile females as defined in MIL-STD- 1472G while the vehicle is upright and the operator is standing on ground with a 5% (1:20) crown (plane of the 4 wheels)

D , I, T The government will measure the system and perform HFE testing to verify compliance with the requirement

3.8.6 The system's first responder shall be labeled to indicate intended use and lock and unlock positions as defined in MIL-

STD-1472G

I The government will inspect the system to verify compliance with the requirement

3.8.7 The first responder receptacle shall be located on the exterior of the rear door(s) or utilize the existing receptacle.

I The government will inspect the system to verify compliance with the requirement

3.9 Transparent Armor

3.9.1 The transparent armor shall be compliant with protection class 3A of ATPD 2352 Revision P (T) Revision R (O) purchase description, transparent armor.

C, T The vendor will provide certification to verify that the transparent armor meets the purchase description

3.9.2 The transparent armor shall be 55 lbs/ft^2 or less (T) T, C The vendor will provide certification and the government will weigh the transparent armor to verify is 55 lbs/ft^2 or less

3.9.3 The transparent armor shall be 44 lbs/ft^2 or less (O) T, C The vendor will provide certification and the government will weigh the transparent armor to verify is 43 lbs/ft^2 or less

3.9.4 The system's transparent armor shall not be thicker than 5.4 inches (T)

I The vendor will provide a detailed design review and the government will measure to verify the transparent armor’s depth is not greater than the current transparent armor

3.10 Primary/Service Lock Handle

3.10.1 The system shall include a primary/service lock. I The government will inspect the primary/service lock

3.10.2 The system’s primary/service lock interior handle shall fully disengage both the primary/service lock, the secondary/combat lock, and activate the door assist within 1 second in one step

D, T The government will verify compliance with the requirement

3.10.3

The system's primary/service external handle shall be accessible along its entire range of motion by 95th percentile males and 50th percentile female (T), 5th percentile female (O) while the vehicle is upright and the operator is standing on ground with a 5% (1:20) crown wearing protective gear (MOPP IV, ballistic protection and gloved hands) in accordance with the applicable sections for Ground vehicles (5.6.1), Physical accommodation (5.8) and Anthropometric design (5.8.4) of MIL-STD-1472G

D,I, A The vendor will provided analysis, and the government will measure the system and verify compliance with the requirement

3.10.4

The system's primary/service interior handle shall be accessible along its entire range of motion by 95th percentile males and 50th percentile female (T), 5th percentile female (O) while the operator is belted in a seated position and wearing protective gear (MOPP IV, ballistic protection and gloved hands) in accordance with the applicable sections for Ground vehicles (5.6.1), Physical accommodation (5.8) and Anthropometric design (5.8.4) of MIL-STD-1472G

D, I, A The vendor will provided analysis, and the government will measure the system and verify compliance with the requirement

3.10.5 The force required to operate the primary handle shall be no more than 12 ft-lbs resistance in any vehicle orientation (T)

T The government will operate the system to verify the force requirement to operate the system

3.10.6 The force required to operate the primary handle shall be no more than 6 ft-lbs resistance in any vehicle orientation (O)

T The government will operate the system to verify the force requirement to operate the system

3.11 Secondary/Combat Lock

3.11.1 The system shall include a secondary/combat lock. I

The government will inspect to verify the system includes a secondary/combat lock.

3.11.2 The secondary/combat lock shall have the ability to be activated/deactivated independently of the primary/service lock

D The government will operate the system to verify the force requirement to operate the system

3.11.3

The secondary/combat lock internal interface shall be accessible throughout its full range of motion by 95th percentile males and 5th percentile females as defined in MIL-STD-1472G while wearing protective gear (MOPP IV, ballistic protection and gloved hands)

D, T The government will measure the system and perform HFE testing to verify compliance with the requirement

3.11.4 From outside the vehicle, the secondary/combat lock shall only be capable of being disengaged through use of the first responder mechanism.

D The government will test the system to verify the requirement

3.11.5 The force required to operate the secondary handle shall be no more than 12 ft-lbs (T) resistance in any vehicle orientation

T The government will test the system to verify the force required to operate the system

3.11.6 The force required to operate the secondary handle shall be no more than 6 ft-lbs (O) resistance in any vehicle orientation

T The government will test the system to verify the force required to operate the system

3.12 Rear Steps

3.12.1 The rear steps shall not prevent egress when subjected to any threats (MPB), 2.6x UBIED, 360-degree rollover, or any other common event

A, T the government will perform analysis and ballistic tests to verify compliance with the requirement

3.12.2 The rear steps shall be removable at 2 single handed release points (T)

D,T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.3 The rear steps shall be removable at 1 single handed release point (O)

D,T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.4 If the rear steps are stowable, they shall require 31 lbs. or less of force to be stowed/deployed while the vehicle is in any orientation.

T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.5 The rear steps shall be removed in no more than 10 seconds (T)

T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.6 The rear steps shall be removed in no more than 5 seconds (O) T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.7 The rear steps shall require no more than 4 single handed procedures to be removed (T)

D, T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.8 The rear steps shall require 1 single handed procedure to be removed (O)

D, T The government will perform HFE tests on the system to verify compliance with the requirement

3.12.9 The rear steps’ release points shall be protected from inadvertent release.

T, D The government will perform a removal test removal scenarios as well as test ground contact to verify the system does not inadvertently release from the vehicle

3.12.10 The system shall be labeled to indicate removal points and procedures IAW MIL-STD-1472G

I The government will inspect the system to verify compliance with the requirement

3.12.11 The rear steps in their vehicle operating configuration shall not degrade vehicle mobility

T The government will perform mobility tests to verify compliance with the requirement

3.12.12 The rear steps shall be stowable as to avoid contact with the ground or any other obstacle while driving (O).

D, T The government will perform endurance tests to verify compliance with the requirement

3.12.13 The rear steps shall not interfere with the rear doors operation, emergency egress capability, or effect the performance in any way as define in this performance specification

D The government will operate the system to verify compliance with the requirement

3.12.14 The rear steps shall be IAW MIL-STD-1472G for riser, tread dimensions. The maximum distance from the ground, while the vehicle is upright on flat level ground, shall be 18 inches.

I The government will inspect the system to verify compliance with the requirement

3.12.15 The system’s steps shall not degrade current towing capabilities to include but not limited to trailers like-vehicle towing, and recovery operations (T)

D, T The government will perform tow testing to verify compliance with the requirement

3.12.16 If the rear steps are removed for towing, provisions shall be provided to transport steps (O)

D The government will operate the system to verify compliance with the requirement

3.12.17 Rear steps shall not be removed for towing (O) D

The government will operate the system to verify compliance with the requirement

3.12.18

The rear steps shall not reduce the approach/departure angle for all CAT I/II A1/A2 vehicles (T). Note: if the rear steps are stowable, departure angle will be calculated with steps in the stowed position.

A, I The government will take measurements to verify compliance with the requirement

3.12.19

The system shall increase the approach/departure angle for all CAT I/II A1/A2 vehicles (O). Note: if the rear steps are stowable, departure angle will be calculated with steps in the stowed position.

A, I The government will take measurements to verify compliance with the requirement

3.13 Durability, Strength, and Performance

3.13.1

The system shall retain material safety, integrity, and performance within a hot environment after being exposed to induced air heat during storage and transit in a hot dry environment.

T

The government will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Method 501.5 Procedure I – Storage -Follow Table 501.5-III -7 Cycles with daily high of 160 degF -Conduct before 501.5 Procedure II but after 505.5 procedure I

3.13.2

The system shall retain material safety, integrity, and performance within a hot dry environment.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Method 501.5 Procedure II – Operation at constant hot temperature -Maximum is 130 degF -Exposure to 3, 24 hr cycles

3.13.3

The system shall retain material safety, integrity, and performance within a cold environment.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Method 502.5 Procedure II – Operation at constant cold temperature -Temperature: -25 degF -Maintain temperature 24 hrs

3.13.4

The system shall retain material safety, integrity, and performance after being temporarily exposed to contaminating fluids.

C, T

The vendor will provide certifications and the Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Test Method 504.1 Procedure I – Large vehicles -Contaminating fluids include fuels, hydraulic fluids, lubricating oils, solvents, and cleaning fluids, de-icing and anti-freeze fluids, insecticides, disinfectants, coolant dielectric fluid, and fire extinguishers

3.13.5

The system shall retain material safety, integrity, and performance during and after exposure to directional heating effects of solar radiation experienced in a hot dry climate.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Method 505.5 Procedure I – Cycling per Figure 505.5-1

- 7 cycles (24 hr/cycle) -Only exterior components exposed to solar -Conducted prior to method 505.1

3.13.6

The system shall retain material safety, integrity, and performance and water tight seals shall not leak during and after exposure to effects of windblown rain.

C, T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Method 506.5 Procedure I – Rain and Blowing Rain -Rainfall Rate: 4 in/hr -Wind Velocity: 70 mph -Exposure: Each vehicle side, 1 hour of exposure per side

3.13.7

The system shall retain material safety, integrity, and performance during and after exposure to effects of high humidity and heat.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Test Method 507.5 Procedure II –Induced (storage and transit) variable-high humidity (95% or greater with hot temperatures).

-90 B4 cycles

3.13.8

The system shall retain material safety, integrity, and performance during and after exposure to physical, electrical, and corrosive effects of salt fog.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Test Method 509.5 -5% salt fog mist concentration -Two 42 hour periods of exposure and two 24 hour period of drying time

3.13.9

The system shall retain material safety, integrity, and performance during and after exposure to effects of sand and dust.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Test Method 510.5

- Procedure I and Procedure II

- 40 mph blowing dust with particles less than 149 µm and sand with particles of 150 µm—850 µm -Concentration 1.6 + or – 7g/m3

-6 hour exposure ambient and 6 hours operating temperatures

3.13.10

The system shall retain material safety, integrity, and performance during and after exposure to effects of fresh water immersion.

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Test Method 512.5 -Procedure I – Immersion -30 minute duration in 4 meters of water after water pressure has equalized

3.13.11

The system shall retain material safety, integrity, and performance during or after vehicle travels over terrain operations as defined in the MRAP Operational Mode Summary

T

The Cougar Program Office will test the system using the following procedures to verify compliance with the requirement.

MIL-STD-810G Test Method 514.6 -Procedure I, Annex D, Category 20.

Primary road 0.1 to 0.3 RMS 10% of profile Secondary road 0.3 to 1.0 RMS 40% of profile Trails 1.0 to 3.4 RMS 30% of profile Cross Country 1.5 to 4.8 RMS 20% of profile

3.13.12

The system, subsystems, and equipment shall include the necessary electrical bonding to meet the E3 requirements of MIL-STD-464C paragraph 5.11 (also see appendix paragraph A.5.11 of standard for guidance).

A, T

The contractor will provide analysis and the Cougar Program Office will test the system to evaluate bonding and grounding of system components per MIL-STD-464C para 5.11.

3.13.13 The system shall not be susceptible to Hazards of Electrostatic Discharge to/from personnel per MIL-STD-464C paragraph 5.8.

A, T The contractor will provide analysis and the Cougar Program Office will test the system to verify it is not susceptible to hazards of electrostatic discharge.

3.13.14 The system design shall protect personnel from hazardous effects of electromagnetic radiation (HERP) per MIL-STD-464C paragraph 5.9.1.

A, T

The contractor will provide analysis and the Cougar Program Office will test the system to verify and protect personnel from hazardous effects of electromagnetic radiation (HERP) per MIL-STD-464C section 5.9.1.

3.13.15 The system design shall protect ordnance from hazardous effects of electromagnetic radiation (HERO) per MIL-STD-464C section 5.9.3.

A, T

The contractor will provide analysis and the Cougar Program Office will test the system to verify protect ordnance from hazardous effects of electromagnetic radiation (HERO) per MIL-STD-464C section 5.9.3.

3.13.16

The system design shall protect fuel from hazardous effects of electromagnetic radiation (HERF) per MIL-STD-464C section 5.9.2.

A,T

The contractor will provide analysis and the Cougar Program Office will test the system to verify protect fuel from hazardous effects of electromagnetic radiation (HERF) per MIL-STD-464C section 5.9.2.

3.13.17 The system shall meet Electromagnetic Compatibility (EMC) requirements when integrated into the vehicle per MIL-STD- 464C paragraph 5.2.

A,T The contractor will provide analysis and the Cougar Program Office will test the system to verify compliance with MIL-STD- 464C paragraph 5.2.

3.13.18

The system shall be electromagnetically compatible with its defined external RF EME such that its performance requirements are met. For ground systems, MIL-STD-464C TABLE 4 shall be used.

A, T

The contractor will provide analysis and the Cougar Program Office will test the system to verify the system meets requirements specified in this document, during and after exposure to electromagnetic radiation in accordance with the External RF Electromagnetic Environment (EME) requirements, as specified in MIL-STD-464C.

3. 13.19 The system shall not reduce the vehicle’s mean time between operational mission failure to less than current MPB values

T The government will perform full up systems level endurance testing with the system installed to verify mean time between hardware failure

3. 13.20 The system shall be functional after 20,000 miles of the MRAP mission profile as defined in the MRAP Operational Mode Summary

D The government will operate the…