Attachment_A_-_MCTWS_Performance_Specification.docx

INCH-POUNDS

2 Jun 14

PERFORMANCE SPECIFICATION

MARINE CORPS TACTICAL WELDING SHOP

1. SCOPE

1.1. Scope. This performance specification describes a Marine Corps Tactical Welding Shop (MCTWS) consisting of selected tools and equipment integrated within a storage enclosure and mounted on a trailer chassis. The MCTWS will enable qualified personnel to perform a variety of common weld processes for maintenance and repair to military equipment. The MCTWS shall be configured with an engine powered welder(s) capable of field weld repair for outdoor operations and with plug-in non-engine-powered welding for indoor operations.

2. APPLICABLE DOCUMENTS

2.1. Government Documents

2.1.1. Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks are part of this document to the extent specified herein. Unless otherwise specified in the procurement acquisition document, the latest revision of these specifications and standards at time of solicitation shall be adhered to. Documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS). Unless otherwise indicated, copies of federal/military specifications, standards, and handbooks are available from the Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094

FEDERAL STANDARDS

DEPARTMENT OF DEFENSE STANDARDS

2.2. Other Publications. The following document(s) form a part of this document to the extent specified herein.

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI Z535.4 Product Safety Signs and Labels (Application for copies should be addressed to the American National Standards Institute, 11 W. 42nd Street, New York, New York 10036.)

AMERICAN WELDING SOCIETY (AWS)

Welding Handbook (Copies of this handbook are available from the American Welding Society, 550 NW LeJeune Road, P.O. Box 351040, Miami, FL 33135)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE), INC.

(Application for copies should be addressed to the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096)

TEST OPERATIONS PROCEDURES

2.3. Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations.

3. REQUIREMENTS

3.1. General. All components or accessories required to meet this document shall be furnished and intracompatible with the MCTWS. The MCTWS shall be provided with the necessary operating accessories customarily furnished with equipment of this type together with such attachments necessary to enable the MCTWS to function in accordance with the requirements stated herein. The MCTWS shall conform to all Federal Laws and regulations governing safety, noise levels and pollution, which are in effect on the date of solicitation or publicly known to be scheduled for implementation during the performance of the contract.

3.2. Materials. Material not specified herein shall be selected by the contractor and will be subject to all requirements of this performance specification.

3.2.1. Welding. All welding shall meet the design and fabrication requirements for weldments, in accordance with American Welding Society (AWS) Standards. Welding requirements also apply to subcontractors and shall be incorporated in the contractor vendor quality control program. It is the responsibility of the contractor to ensure strict compliance to the required welding standards and qualifications. All weld personnel and welding equipment shall pass qualification tests as prescribed by the AWS Standards.

3.2.2. Material Deterioration Prevention and Control. The MCTWS shall be fabricated from compatible materials, inherently corrosion resistant or treated to provide protection against the various forms of corrosion. Metal parts shall be corrosion resistant materials, galvanized, or shall be coated for protection from corrosion.

3.2.3. Dissimilar Metals. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion. Dissimilar metals and methods of protection are defined and detailed in MIL-STD-889.

3.2.4. Hazardous Material. The use of hazardous material shall be avoided when a non-hazardous alternative is available which meets the performance requirements.

3.2.5. Ozone Depleting Substances. All materials and components shall be free of ozone depleting substances per applicable Federal regulations.

3.2.6. Ozone Resistant Products. All polymer products shall be ozone resistant consistent with best commercial practice.

3.3. Operational Performance. The MCTWS shall be a self-contained, integrated unit equipped for safe performance of welding and welding-related processes. The MCTWS shall contain the work tools, accessory equipment, and consumable supplies necessary to perform these processes. MCTWS components shall be mounted on the trailer and plumbed or wired as necessary to form an integrated, fully functional unit.

3.3.1. Engine Driven Weld Unit. The MCTWS shall simultaneously provide welding capability, compressed air on demand, plasma cutting capability, and at least 3kVA of 120V AC electrical power for lights and power tools.

3.3.1.1. Engine. The MCTWS shall have a multi-fuel engine(s), governed for constant speed, which is capable of meeting all requirements of this performance specification while operating with diesel or JP-8. Engine fuel system shall have a 2,000 hour life without the use of additives added to the fuel tank. The vendor shall use the highest TIER level engine available that is compatible with JP-8. The multi-fuel engine(s) is used when the MCTWS is operated outdoors.

3.3.1.2. Utility Power. The MCTWS shall include the capability to use plug-in electric power (utility power) for indoor use. A 50 ft. cable shall be provided with adapters for connecting the MCTWS to NEMA L15-30R receptacles for utility power. All MCTWS components shall run off of a single cable to utility power except the three phase devices can be run separately off of the same utility power cable. When operating the three phase devices from utility power, the MCTWS 110 volt devices can be run off a 110 volt extension cable supplied by the facility. Concurrent operations are not required when running off of utility power. Derating of the 300 amperes, 32 volts, at 60 percent duty cycle weld output when operating from utility power is acceptable but the welder shall be integrated to obtain the maximum input power available from utility power.

3.3.1.3. Weld Output. The weld unit shall provide at a minimum 300 amperes and at least 32 volts DC on a 60 percent duty cycle. Derating of the 300 amperes, 32 volts, at 60 percent duty cycle weld output when operating above 9,000 feet elevation and using JP-8 fuel at 77 degrees Fahrenheit. The output shall be fully adjustable across the operating capacity of the weld unit.

3.3.2. Arc Welding Processes. The MCTWS shall provide the capability to perform the following arc welding processes as defined by the AWS Welding Handbook: Shielded Metal Arc Welding (SMAW), Flux Core Arc Welding (FCAW), Gas Tungsten Arc Welding (GTAW), and Gas Metal Arc Welding (GMAW).

3.3.2.1. Gas Metal Arc Welding (GMAW). Equipment necessary to perform GMAW welding, including Pulsed GMAW (GMAW-P), operations shall be provided. A lightweight GMAW gun and wire feeder shall be provided to facilitate access to restricted space. The wire feeder shall be separate from the gun, and the welding head shall use the appropriate inert gas as a shield during welding.

3.3.2.1.1. Spool Gun. A Millermatic 30A spoolmatic gun with WC-24, or equivalent, shall be provided. Equivalency shall be determined by the following factors:

· 200 amps

· 100 volts

· 100% duty cycle

· 0.025-0.0625 inch wire diameter

· 4 inch spool diameter

· Wire speed adjustment knob on handle

· 15 foot cable length

3.3.2.1.2. GMAW Gun. A Miller Roughneck C4015 GMAW gun, or equivalent, shall be provided. Equivalency shall be determined by the following factors:

· 400 amps

· 0.035-0.045 wire diameter

· Flex head kit provided

· 15 foot cable length

3.3.2.1.3. Suitcase Wire Feeder. A Miller 12VS suitcase wire feeder, or equivalent, shall be provided. Equivalency shall be determined by the following factors:

· Automatic feed at controlled rates

· Automatic burn rate adjustment

· Provisions for mounting commercially available wire reels of 10-25 lbs.

· Utilized for both soft wire GMAW and intershield (flux core) welding

· Separate units to cover these two welding types is allowable

3.3.2.1.4. Pulse control. The MCTWS shall have a remote pulse controller.

3.3.2.2. Gas Tungsten Arc Welding (GTAW). The GTAW welding unit shall be a compact and rugged unit compatible with the welding machine.

3.3.2.2.1. GTAW Torch. A Miller A-200 Flex Valve GTAW torch, or equivalent, shall be provided. Equivalency shall be determined by the following factors:

· 200 amps

· Cooled by air

· 25 foot cable length

3.3.3. Cutting Processes. The MCTWS shall provide the following cutting capabilities.

3.3.3.1. Plasma Cutter. A plasma cutter shall be provided and have the ability to pierce and cut 3/8” steel plate.

3.3.3.2. Oxy-Acetylene Torch. An industrial grade oxy-acetylene torch set compatible with tips specified in Table III shall be provided.

3.3.3.3. Exothermic Cutter. An exothermic cutter shall be provided that is compatible with rods listed in Table III.

3.3.4. Armor Processes. The MCTWS shall include, at a minimum, a carbon dioxide gas cylinder and a gas mixing device for arc welding ferrous armor. The gas mixing device shall be capable of producing a 75/25 ratio of mix with a flow rate compatible with GTAW welding operations specified.

3.3.5. Gas cylinders. The MCTWS shall have gas cylinders and provisions to mount gas cylinders of sufficient volume for operating the MCTWS to include, but not limited to, oxygen, acetylene, argon, and carbon dioxide. Cylinder volumes listed in Table I are minimums. Each cylinder provided shall have a flow regulator. Provisions provided for mounting cylinders shall be adjustable and accommodate the dimensions listed in Table I. Cylinders shall be empty when MCTWS units are shipped from the contractor. Cylinder colors shall meet MIL-STD-101. Gas cylinders shall be stored in a location on the MCTWS such that cylinder temperature does not exceed 125 degrees Fahrenheit during welding operations at all temperatures specified in section 3.7.3.

Table I. Cylinder specifications

3.3.6. Air Compressor. An electric air compressor shall be provided. The air compressor shall be capable of supporting plasma cutting operation at 100% duty cycle and integrated into the MCTWS in such a way that prevents overheating and have a minimum output of 6.5 cfm delivered at 90 psi.

3.3.7. Operational Distance. The MCTWS shall support operation of electric power tools, air tools and lights as well as conduct all welding, brazing and cutting processes, without tension, within a 50 foot reach from the center of the trailer.

3.3.8. Linear Products. Flexible linear products, such as gas hoses, electrical cables, and electrode cables that are twenty five feet in length or greater shall be stored on spring loaded reels. Flexible linear products that are less than twenty five feet in length shall be stored on mounting brackets or in storage containers. All compressed air hoses shall have quick disconnect fittings.

3.3.9. Work Surface. The workbench shall be at least 88 inches wide and 18 inches deep and integral with the MCTWS structure (T). In addition, a work surface of at least three square feet shall be capable of being integrated with the workbench to create an “L” shape workspace (O). The configuration of the MCTWS and workbench shall allow the welders to reach the controls and indicators on the engine driven welder from the workbench area. The work surface shall be 36±3 inches from ground level when the MCTWS is fully laden and prepared for operation. The work surface shall be a non-flammable, durable surface capable of withstanding impacts and temperatures typical of repair welding operations without sustaining damage such as damage from weld spatter and warping. The integrated workbench and additional work surface shall be capable of supporting a load of at least 500 pounds without being damaged. The workbench may be collapsed for storage and transportation to meet MCTWS dimensional requirements.

3.3.9.1. Slag Protection. The MCTWS shall provide component protection against damage from slag while welding on the work surface.

3.3.10. Vise. The MCTWS shall contain a vise that can be removed and stowed without the use of tools. The vise shall be at least a five inch vise to allow for securing items parallel and perpendicular to the axle of the trailer. The MCTWS shall provide a mount for the vise on or near the workbench. When mounted, the vise shall have the full range of motion and uses anticipated by its design. When mounted, the vise shall be afforded at least one position free of obstructions in the vertical plane of its jaws. The vise shall include a mechanism to tighten the vise to inhibit movement.

3.3.11. Lighting. The MCTWS shall provide mounted light(s) for the workbench. The workbench light(s) shall provide an illumination of at least 50 foot candles, as measured at the work surface. Illumination levels shall be as specified and light shall be so distributed as to minimize glare and specular reflection.

3.3.12. Work Tools and Accessory Equipment. The MCTWS shall contain the work tools and accessory equipment listed in Table III. The work tools and accessory equipment provided with the MCTWS shall be of sufficient durability to withstand operating in an expeditionary environment. The work tools and accessory equipment shall be professional grade equipment and of a quality provided by manufacturers such as Craftsman, Dewalt, Lincoln, Miller or equivalent. When work tools and accessory equipment require batteries to operate battery chargers shall be provided. A Basic Operators Bag (BOB) Tool Kit, NSN 5180-01-580-7176, for each MCTWS will be provided as GFE. The entire BOB, as provided, shall be part of the MCTWS tool set.

3.3.12.1. Welding Helmet. A welding helmet shall be provided to protect personnel during operation of the MCTWS. The welding helmet shall have an adjustable headband, weigh less than two pounds, and include a viewing area of at least 4 inches wide by 4 inches tall. The weld helmet must also provide a flip-up/flip-down lens capability.

3.3.13. Slaving Components. The multi-fuel engine (s) shall be equipped with a 24 volt slave receptacle conforming to MIL-PRF-62122. The slave receptacle shall permit charging of the batteries and slave starting of the engine from an external power source. The slave receptacle shall be installed near the battery enclosure and shall be accessible to personnel standing on the ground. The receptacle shall be labeled “Slave, 24 Volts”.

3.4. Physical Characteristics

3.4.1. Trailer. The MCTWS shall be an enclosed trailer mounted system.

3.4.1.1. Braking. The trailer shall be equipped with a brake system that is controlled by the Marine Corps Medium Tactical Vehicle Replacement’s (MTVR) air brake system. Brakes shall be self-adjusting and shall comply with FMVSS and FMCSR in effect at the time of contract award to specifically include FMCSR 393.40, FMCSR 393.41, FMCSR 393.42, FMCSR 393.43, FMCSR 393.45, FMCSR 393.47, FMCSR 393.48, FMCSR 393.49, FMCSR 393.50, FMCSR 393.52, FMCSR 393.55, FMVSS 121 (air brake systems only), and FMVSS 106.

3.4.1.2. Service Brakes. The trailer shall be equipped with service brakes. The service brakes shall be in accordance with FMVSS, CFR 49, chapter 571.121 for air brakes. The brake linings shall be of non-asbestos material. The combined service brakes of the trailer and towing vehicle shall, under all conditions of loading, bring the combination to a positive stop within 35 feet (ft) (9.1 meters (m)) from a speed of 20 mph (32.2 km/h) on a dry, smooth, and level hard surfaced road, free of loose material. When coupled to an MTVR, the trailer service brakes shall control and hold the trailer on a dry hard surfaced 45% longitudinal slope in both ascending and descending orientations. Upon completion of TOP 2-2-608 no further servicing of the brake system shall be required to return the brake system to a fully operational capability, other than adjustment/replacement of brake shoes/pads. No permanent deformation of any component, other than shoes/pads, is allowed.

3.4.1.3. Emergency Brakes. The trailer shall have emergency brakes that apply automatically in the event of air pressure loss from the MTVR and are equipped with a manual override that will allow the trailer to move. The override shall be operable by the operator using only tools listed in Table III within 30 minutes.

3.4.1.4. Parking Brake. A manually operated parking brake shall hold the trailer with cross-country payload on a dry, hard, smooth-surfaced road on a 30% grade while unrestrained by the towing vehicle at the pintle and headed up or down grade.

3.4.1.5. Anti-lock Brake System (ABS). The trailer shall be equipped with an ABS that shall be compatible with the MTVR’s ABS unless a trailer already in the Army inventory is selected that does not have ABS. The power to actuate the trailer’s ABS shall be provided by the MTVR.

3.4.1.6. Standalone Stability. The trailer at curb weight and max payload shall not tip over in any direction when uncoupled from a towing vehicle on or up to a 10% slope. Once uncoupled from the MTVR, the trailer at curb weight and max payload shall be capable of being re-coupled to the MTVR on or up to a 10% slope.

3.4.1.7. Lunette and Landing Legs. The lunette shall comply with A-A-52464. The lunette landing gear shall be capable of withstanding 4.5g download of the static load on the landing legs.

3.4.1.7.1. Adjustable Lunette. The lunette for the MCTWS shall be adjustable to accommodate interfacing to a fully loaded, partially loaded, and unloaded MTVR, armored or unarmored, across all terrain types. The lunette shall be adjustable from 26.9 inches to 40.8 inches. The trailer shall be level when interfacing with the MTVR in all states.

3.4.1.8. MTVR Pintle Interface. The vertical load exerted upon the pintle of the MTVR shall not exceed 900 lbs. when the trailer is loaded to maximum forward-biased payload. The trailer shall comply with FMCSR 393.70. The trailer shall conform to the provisions of SAE J684.

3.4.1.9. Interface Requirements. The trailer shall conform to this specification and interface with all variants of the MTVR. The trailer shall meet the NATO requirements of standardization of voltage STANAG 2601, braking and brake interoperability between tractor and trailer STANAG 2604, electrical connections STANAG 4007, and blackout lighting systems STANAG 4381.

3.4.1.10. Receptacles. The trailer shall be equipped with one 12-contact receptacle with cover, and one 7-contact receptacle with cover installed at the front of the trailer. The 12-contact receptacle shall conform to MS75021-1 and be equipped with a cover assembly conforming to drawing 7731428, nut grommet, retainer conforming to drawing 7723309, and grommet, electrical connector conforming to drawing 7722333. The 7-contact receptacle shall conform to SAE J560 round socket with cover for an intermediate connector cable. Both receptacles are to be located as required by SAE J702. These receptacles are to be interconnected without the use of circuit breakers. Interconnections between the 12-contact and 7-contact receptacles shall be as per Table II below.

Table II. 24V connector pin assignments

3.4.1.11. Electrical Harness Requirements. All electrical harness connections shall be water tight, environmentally sealed, positive retention type to protect it from rain, road spray, etc. Wiring shall be secured to prevent chaffing and loose connections.

3.4.1.12. Lighting. Lighting shall be IAW MIL-STD-1179 requirements for trailers. A license plate light is not required. The use of Light Emitting Diode (LED) technology is encouraged.

3.4.1.13. Blackout Lighting. The trailer shall be equipped with blackout lighting IAW MIL-STD-1179 Paragraph 4.5. The trailer blackout lighting shall interface with the MTVR blackout lighting and controls.

3.4.2. Weight. The weight of a complete MCTWS, when fully loaded, shall not exceed 9,000 lbs. (T). The objective is for the system is 8,700 lbs. (O) and shall be capable of accommodating an additional 300 lbs. of miscellaneous equipment without exceeding the 9,000 lbs. threshold.

3.4.3. Ground Clearance. When fully laden, the MCTWS shall negotiate the roadability and maneuverability requirements stipulated in this performance specification, but in no case have a ground clearance of less than 15 inches.

3.4.4. Size. The overall dimensions of the MCTWS, when ready for towing, shall not exceed the following dimensions: 81 inches high, 97 inches wide, and 175 inches long.

3.4.5. Balance. When prepared for storage, the weight of MCTWS shall be balanced on the chassis. The center of gravity shall be forward of the trailer axle such that the tongue lunette weight is not less than 5% of the trailer’s weight or in excess of 900 pounds.

3.4.6. Stability. When set up for operation, the weight of the MCTWS shall be balanced on the chassis. The center of gravity shall be located such that, with the stabilizer(s) in a stowed position on the trailer, a downward force of 500 pounds can be applied to the work surface without causing the trailer to tip.

3.4.6.1. Stabilizer. The trailer shall be provided with fold-up support legs attached to the rear of the trailer frame that will protect the user from tip-over in the event of an overloaded work surface. The stabilizer(s) shall be adjustable in length and deployable within 2 minutes.

3.4.7. Roadability. The MCTWS shall be structurally adequate and sufficiently durable to withstand being towed behind an MTVR across a mission profile of 10% primary roads (RMS <0.2 inches), 60% secondary roads (0.2 inches<RMS<1 inch), and 30% cross-country (1inch<RMS<4.8 inches). The MCTWS shall be capable of being towed at speeds of 45 miles per hour (mph) on primary roads, 20 mph on secondary roads, and 10 mph cross-country. All items shall remain in their rapid inventory location and be secured and protected from damage induced by traversing the above Transport Profile. Protective measures may include providing suitable springs and dampers (shock absorbers) to the trailer suspension and suitable shock mountings and restraints for the components loaded or installed on the MCTWS.

3.4.8. Maneuverability. The trailer, at maximum payload, when coupled to the MTVR at CCGVW, shall be capable of ascending and descending a reinforced surface with a 45% longitudinal slope and traversing a 30% reinforced surface side slope while executing a sinusoidal maneuver around obstacles with no tire lift at 15 mph. Minimum turn radius for the sinusoidal maneuver shall be 40 feet. Maneuverability tests shall be performed in accordance with TOP 2-2-610.

3.5. Enclosure. The MCTWS equipment and supplies shall be mounted in a lockable enclosure that discourages tampering, unauthorized use, and theft of the MCTWS and MCTWS components.

3.5.1. Shelter. The work surface and the user shall be sheltered from adverse conditions when the weld shop is in use and the enclosure shall provide support for weld curtains. The cover shall be deployable by one person and provide the weld shop a top cover and security when lowered for stowage.

3.5.1.1. Welding Curtains. The shelter hard cover shall provide the means to secure translucent welding curtains to protect personnel not wearing the appropriate eye protection, and capable of being set up within five minutes.

3.5.2. Storage. The MCTWS shall have integral storage compartments suitable for stowing all equipment, publications, and consumable supplies during transportation, storage, and periods of non-use.

3.5.2.1. Organized Storage. Each item carried in the MCTWS shall have a specifically designated storage location.

3.5.2.2. Proximate Storage. Items for welding and maintenance operations normally used together shall be stored in the same area of the MCTWS enclosure.

3.5.3. Rapid Inventory. The design of the MCTWS shall facilitate rapid inventory. Storage methods employed should enable the operator to verify within thirty (30) minutes or less that all items are present and secured in their designated storage locations. In the event an item is absent from the shop, the operator shall be provided with the means to identify the specific item by name and description.

3.5.3.1. Visual Cues. The storage method used for each item shall provide the operator a visual cue when an item is not in its designated storage location. Any missing item in a container’s grouping be identifiable within one minute.

3.5.4. Storage Restraints. Straps, brackets, clamps or other devices shall be provided to assure that all stowed items remain securely in place and are protected from damage during transportation.

3.5.4.1. Component Restraints. Doors, drawers and other moving parts of the enclosure and the storage system shall be provided with restraints as necessary to secure them in the open and closed positions. The restraints shall prevent unintended movement of the moving parts due to wind, the transportation profile in section 3.4.7., or placement of the MCTWS on a slope. Items stored in the MCTWS shall be provided with restraints to secure them in place. The restraints shall prevent the stored items from sliding or falling out of their storage locations when the MCTWS is being towed, transported, or placed on 15 degree slopes.

3.5.5. Locks. Locking of the enclosure shall be accomplished with key-operated, tumbler-type padlocks, listed in Table III. The number of locks required to secure each MCTWS shall not exceed four. If multiple locks are used the set of locks for each MCTWS shall be keyed alike, and the keys used for one set shall not work for any other set. No master or grand master keys shall be provided. Each padlock shall be permanently attached to the MCTWS enclosure with a rust proof flexible aircraft cable at least 12 inches in length. When prepared for towing and storage, the padlocks on the enclosure shall be plainly visible. It shall not be possible to use or remove any of the equipment stored in the enclosure without either removing the locks or visibly damaging the enclosure. All doors, panels, and other covers for openings in the MCTWS enclosure shall be permanently affixed to the enclosure. Doors and panels shall be contained in the enclosure or lie flat against it when open.

3.6. Human Factors. The MCTWS shall be suitable for operation and maintainable 5th percentile female through 95th percentile male military personnel as defined by MIL-STD-1472.

3.6.1. Task Loading. The MCTWS shall be capable of being prepared for operation, or storage and transportation within fifteen minutes. Setup and operation of the MCTWS shall not require more than one person.

3.6.2. Easy Access. All equipment and consumable supplies stored within the MCTWS shall be accessible by personnel standing on the ground next to the MCTWS.

3.6.3. Free Movement. The MCTWS enclosure doors and storage areas shall minimize impediments to the operator, and interference with use of the shop caused by obstacles (e.g. rocks, posts, and trees) standing within two feet of the trailer sides.

3.7. Environment

3.7.1. Operational Environment. The MCTWS shall meet operational requirements, in section 3.3., in climatic design types between and including hot and basic cold as defined by MIL-STD-810. The MCTWS shall operate under the adverse weather conditions of these climatic design types, excluding welding operations in the rain. A 30 minute warm up period is allowed for operation in basic cold.

3.7.2. Storage Environment. The MCTWS shall withstand outdoor storage in climatic design types from basic cold as defined by MIL-STD-810 to +125° F without sustaining damage to the enclosure or any equipment stored within it. The MCTWS shall be stored with all equipment and expendable supplies stowed in their designated positions with all panels and doors closed.

3.7.3. Operating and Storage Temperatures. The MCTWS shall meet operational requirements, in section 3.3., and be capable of storage in temperatures from -28° F to +125° F.

3.7.4. Weather Protection. The MCTWS enclosure shall protect its contents from rain; from accumulations of ice and snow; and, when being towed, from accumulations of road dirt and mud. The enclosure need not be equipped with watertight seals provided the equipment and supplies it contains do not get wet and the water drains from the enclosure. The enclosure shall be vented to permit air circulation during storage.

3.7.5. Fungus and Moisture. The MCTWS electrical circuits and components shall be composed of inherently fungus and moisture resistant materials, or shall be protected from fungus and moisture damage by protective coating(s) or hermetic seal(s). All hoses, electric cable covers and other elastomeric parts that are exposed to air shall be fungus resistant.

3.7.6. Captive Plugs. The MCTWS cables and hoses shall have captive plugs to prevent contamination when cables and hoses are not in use.

3.8. Maintenance. The MCTWS shall be capable of having routine maintenance performed on the arc welding power source without removing the power source from the trailer, and without removing or disassembling the trailer or enclosure. Typical routine maintenance tasks include, but are not limited to: filling the fuel tank; changing the engine oil and filter; changing the engine coolant; replacing the air filter; replacing the fuel filter; checking and maintaining the battery, repairing the spring loaded reels, and cleaning the arc welding power source with low-pressure compressed air. Fluids shall be able to be changed without removing major components.

3.8.1. Cleaning. The enclosure shall be washable inside and out. Any features within the enclosure that could become collection points for water or debris shall be provided with drain holes or access for cleaning.

3.9. Safety. The MCTWS shall not present any uncontrolled safety or health hazards throughout the life cycle of the system. The MCTWS shall incorporate features that assure safe operation. The MCTWS shall have proper ventilation in areas where gas leaks may occur.

3.9.1. First Aid. The MCTWS shall include a first aid kit, NSN 6545-00-922-1200, and a burn kit, NSN 6545-01-526-9237, or equipment of equivalent capability that is readily accessible, to treat minor injuries such as cuts and burns.

3.9.2. Fire Extinguisher. The MCTWS shall include a 10 to 15 pound fire extinguisher that is rated for Class A, B, and C and is readily accessible.

3.9.3. Physical Hazard Control. Mechanical guards, electrical insulation, thermal insulation, and other safety devices shall be provided to protect operators and maintenance personnel from inadvertent contact with moving parts, electrically energized parts, high temperature surfaces, and other physical hazards. The safety devices shall not interfere with operation of the MCTWS. Exposed sharp corners and sharp edges on MCTWS parts shall be eliminated if they serve no functional purpose. Hazards that cannot be eliminated, cannot be controlled by equipment placement, and cannot be controlled by protective devices shall be identified to the user by printed warnings or cautions.

3.9.4. Physical Strain Control. The physical exertion required to set up and operate the MCTWS shall not exceed safe limits for the target population. Caution signs shall be provided for stored items that exceed the safe limits for manual lift (see MIL-STD-1472 for guidance, reference only).

3.9.5. Electrical Enclosure. The MCTWs shall conform to NFPA 70. Electrical enclosures shall meet the requirements of ANSI/NEMA 250. Electrical enclosures that are within the MCTWS enclosure shall conform to NEMA type 3 and electrical enclosures outside the MCTWS enclosure shall conform to NEMA type 4.

3.9.6. Noxious Fumes. There shall be adequate clear space above and below the welding curtains to prevent the accumulation of noxious fumes around the workbench. Engine exhaust from the arc welding power source shall be directed away from the work surface.

3.9.7. Noise Control. The MCTWS shall have warning stickers requiring the operator to wear hearing protection if noise levels are at or above limits set in MIL-STD-1472. Warning stickers shall designate if single or double hearing protection is required IAW ANSI Z535.4. Single and double hearing protection shall be provided with the MCTWS.

3.10. Transportability. The MCTWS shall have the capability of being transported worldwide by rail, marine, highway, and air modes. The MCTWS shall meet the requirements in Title 49 of the Code of Federal Regulations for transportation. Guidance on transportability criteria is defined in MIL-STD-1366.

3.10.1. Rail Transport. The MCTWS shall be rail transportable in the Continental United States (CONUS) and North Atlantic Treaty Organization (NATO) countries. The MCTWS shall be capable of withstanding shock loads resulting from rail impact testing without failure, damage, or permanent deformation per MIL-STD-810 Method 526.

3.10.2. Marine Transport. The MCTWS shall be transportable by US Naval craft to include Semi-Submerged Catamaran (SSC), Landing Craft Air Cushion (LCAC), Landing Craft Utility (LCU), Joint High Speed Vessel (JHSV), Improved Navy Lighterage System (INLS), Amphibious Helicopter Assault Carrier (LHA), Amphibious Helicopter Assault Carrier Dock (LHD), Landing Ship Dock (LSD) and Amphibious Transport Dock (LPD)-17. The MCTWS shall be transportable by Marine Corps Maritime Prepositioning Force (MPF) and commercial shipping. The MCTWS shall be able to traverse Joint Logistics Over-the-Shore (JLOTS) systems, elevated causeways and drive between decks (weather decks, tank decks, and to and from piers) on all vessel ramps without "bottoming out" or causing damage to the transport vessel or MCTWS. The MCTWS shall be equipped with required tie-down provisions for Naval or Joint Shipping in accordance with MIL-STD-209 and MIL-STD 1366. The MCTWS shall be capable of all commercially available loading methods to include, Roll On/Roll Off, Lift On/Lift Off and loaded onto Naval or Joint shipping via the shipping asset’s on-board cranes. The MCTWS shall be capable of negotiating a 17 degree ramp when mounted to the MTVR without the trailer structure contacting the ramp or ground surface. The MCTWS weight shall not exceed 500 pounds per square foot (PSF) (T) or 200 PSF (O) in order to achieve required shipboard transportability.

3.10.3. Highway Transport. The MCTWS shall be transportable by commercial over the road carrier and appropriate military trailers. The contractor shall calculate and provide the maximum allowable payload for unrestricted operation on all US and State Highways based on the vehicle final design, axle weights and spacing.

3.10.4. Air Transport. The MCTWS shall be internally air transportable by C-130, C-17 and C-5 aircraft without preparation, while still maintaining unimpeded flight crew access for routine or emergency access to the vehicle while in flight. The MCTWS shall be capable of cresting 17 degree ramps without any portion of the vehicle, except the tires, contacting ground or ramp surfaces. The MCTWS shall be capable of withstanding flight induced vibration and tensional forces for extended duration flights and shall also be capable of withstanding 8.3 psig within 0.5 seconds (survive rapid decompression environment). See MIL-STD-1791 for design guidance.

3.10.5. External Helicopter Transport. The MCTWS shall be capable of being transported externally by CH-53 helicopter. The use of spreader bars is not permitted.

3.10.6. Lifting and Tie-down Provisions. The MCTWS at Gross Vehicle Weight Rating (GVWR) shall meet lifting and tiedown provision requirements of MIL-STD-209 and MIL-STD 913.

3.11. Treatment and Painting. Unless otherwise specified, all coated surfaces on the modified portions of the MCTWS, shall be coated from bare metal in accordance with USMC TM 4750-OD/1, "Painting, Coating, Underbody and Registration Marking for Marine Corps Combat and Tactical Equipment." The manufacturer shall utilize low Volatile Organic Compound (VOC) content and Hazardous Air Pollutant (HAP)-free coatings, MIL-DTL-53030 and MIL-DTL-64159. All coated parts, unless otherwise specified, shall be green 383, #34094 of FED STD 595. Components not visible and exposed to the outside corrosive environment during normal operation may be painted with the manufacturer's commercial paint and color. All non-military specification coatings must have corrosion resistance similar to the requirements in MIL-DTL-53030. High temperature surfaces, reaching a temperature of at least 400 degrees Fahrenheit, such as exhaust stacks and manifolds shall be coated with a heat resisting paint meeting the qualifications of MIL-PRF-14105 in lieu of CARC coating application. Uncoated surfaces shall be limited to those areas where any coating would interfere with the function of the component. Uncoated surfaces shall be fabricated of materials which are inherently corrosion resistant or treated against corrosion by application of MIL-PRF-81309 Type II corrosion preventative compounds (CPC). Uncoated surfaces shall be treated to, or inherently provide, a surface of limited reflectivity. Parts whose function can be harmed through CPC application, such as hydraulic cylinder rods and seals, shall not be treated. Mating surfaces of structural components, to include wear pads, shall not be topcoated.

3.11.1. Hazard Identification. Unguarded physical hazards (see section 3.9.3.) shall be identified. Product safety signs and labels shall conform to ANSI Z535.4.

3.11.1.1. Lift Hazards. Caution signs shall be provided for stored items that exceed the safe limits for a single person to lift using both hands in accordance with Table XXXVIII in MIL-STD-1472.

3.12. Required Components. If not already included to satisfy a requirement of the performance specification, the MCTWS shall also include the components listed in Table III below.

Table III.

MCTWS

CONSUMABLES, TOOLS & EQUIPMENT

Consumables

Welding Electrodes, Aluminum, 1/8"

Welding Electrodes, Stainless Steel, 1/8", AWS E308-16, E308h-16

Welding Electrodes, Stainless Steel, 3/32", AWS E308-16, E308h-16

Welding Electrodes, Mild Steel, E7018, 1/8", AWS A5.1/A5.1m:2004

Welding Electrodes, Mild Steel, E7018,3/32", AWS A5.1/A5.1m:2004

Welding Rods, 6010, 1/8"

Welding Rods, 6010, 3/32"

Welding Rod, Stainless Steel, 36" Long, 1/16"

Welding Rod, Stainless Steel, 36" Long, 1/8"

Welding Rod, Mild Steel (Oxy-acetylene) , 36" Long, 1/16”,

Welding Rod, Aluminum, 36" Long, 1/16", 5356, AWS A5.10

Welding Rod, Aluminum, 36" Long, 3/32", 5356, AWS A5.10

Aluminum, Spool Wire, 5356/.035", 1-lb Spool, AWS A5.10

Aluminum, Spool Wire, 5356/.047", 1-lb Spool, AWS A5.10

Mild Steel, 7056, L56, .035", AWS A5.18/A5.18m:2005, 33-lb Spool

Mild Steel, 7056, L56, .045, AWS A5.18/A5.18m:2005, 33-lb Spool

Mild Steel, Fluxcored, 71c, .045", AWS E71t1-C-H8, 33-lb Spool

Solder 95/5 For 1/8”, 1 lb Spool

Grinding Wheels 4 1/2” Abrasive Discs, 24 Grit

Grinding Wheels 4 1/2” Abrasive Discs, 36 Grit

Grinding Wheels 4 1/2” Aluminum Grinding Discs

Grinding Wheels 4 1/2” Cutting Discs

4 1/2” Steel Grinding Discs

Grinding Wheels 1/8” X 4 1/2” Grinding Wheels

Hacksaw Blades, 18 Teeth Per”

Hacksaw Blades, 24 Teeth Per”

Hacksaw Blades, 32 Teeth Per”

Size 4 Reciprocating Saw Blades, 14”

Size 4 Reciprocating Saw Blades, 18”

Size 4 Reciprocating Saw Blades, 24”

High Heat Gloves (Pair)

Leather Welding Gloves (Pair)

Leather Welding Jacket

Temperature Crayon, 250°

Temperature Crayon, 500°

Welding Helmet w/ 4" x 4" Flip Up Lens

Replacement Lenses For Weld Helmets (Clear)

Replacement Lenses for Weld Helmets (Shade)

Welding Goggles, 2" x 4 1/4", , Welding or plasma cutting only

Welding Goggles Replacement Lenses, #5 shade w/ glass cover

Welding Blanket

Respirator Mask, Disposable

Safety Glasses

Over-Ear Hearing Protection, Earmuffs

Drag Shield

Swirl Ring

Gouging Tip

Gouging Shield

TIG Gasket Insulator

Soap Stone Or Scribe

Nozzle, 5/8" Orf X 2½" Lg

Nozzle, 5/8" Orf X 1-5/8" Lg

Stainless Steel, 5 lb Bundle

Aluminum Flux Paste

Ear Plugs, Box

Flux Brazing Powder

Aluminum Cleaner, 1 qt.

Flints, Oxy-Acetylene Torch Striker

1/4” Collet Chuck

Washers for Exothrermic Cutter

Plasma Cutter, Two Stage Air Filter

Plasma Cutter, First Stage Element

Plasma Cutter, Second Stage Element

Plasma Cutter, Shield Cup

Plasma Cutter, Start Cartidge

Plasma Cutter, 60 Amp Tip

Plasma Cutter, Electrode

Plasma Cutter, O-Ring

Plasma Cutter, O-Ring

MIG Gun, Gas Diffuser

MIG Gun, .047”, Contact Tip

MIG Gun, .045”, Contact Tip

MIG Gun, .040”, Contact Tip

MIG Gun, .035", Contact Tip

MIG Gun, Centerfire Nozzle

MIG Gun, Centerfire Cap

MIG Gun, Jump Liner

Aluminum Gun, 035”, Contact Tip

Aluminum Gun, 045”, Contact Tip

Aluminum Gun, Nozzle

Aluminum Gun, Gas Diffuser

Aluminum Gun, Nozzle Insulator

Aluminum Gun, Tube Line

Oxy-acetylene Heavy Duty Heating Nozzle (Rose Bud)

Oxy-acetylene Cutting System, Cutting Tips, #1

Oxy-acetylene Cutting System, Cutting Tips, #2

Oxy-acetylene Cutting System, Cutting Tips, #3

Oxy-acetylene Welding Tip SW201

Oxy-acetylene Welding Tip SW203

Oxy-acetylene Welding Tip SW205

Oxy-acetylene Welding Tip SW207

Oxy-acetylene Welding Tip SW209

TIG Torch, Long Back Cap

TIG Torch, Short Back Cap

TIG Torch, 3/32” Collet

TIG Torch, 3/32” Collect Body

TIG Torch, 5/16” Alumiun Nozzle #5

TIG Torch, Alumina Nozzle #4

TIG Torch, Alumina Nozzle #6

TIG Torch, Alumina Nozzle #7

TIG Torch, 040” Collet

TIG Torch, 040” Collet Body

TIG Torch, 1/16” Collet

TIG Torch, 1/16” Collet Body

TIG Torch, Tungsten, 040” 2% Ceriated

TIG Torch, Tungsten, 1/16” 2% Ceriated

TIG Torch, Tungsten, 3/32” 2% Ceriated

Tools

1/2 In Drill Set, High Speed Steel, 1/16-1/2”

1/2” Electric Drill With Handle, Reversible

3/8” Drill Set, Carbide Tipped, 1/16-1/2”

4 1/2” Grinder

7” Grinder

Grinding Wheels 7” Aluminum Grinding Discs

Grinding Wheels 7” Steel Grinding Discs

Air Hammer Set, Includes 3 Chisels

4” C-Clamps

6” C-Clamps

12” C-Clamps

Hacksaw

Metric Allen Wrench Set, 9 Sizes, 1.5-10mm

English Allen Wrench Set, 13 Sizes, .050-3/8”

Sheet Metal Snips, 10”

Automatic Solid Center Punch, 41276” Diameter

Pliers, Diagonal, Cutting, 7 41276”

Rattail File, 10” Bastard

Flat File, 10”

Half-Round File, 12”

Sledge Hammer, 10 lb

Chisel, 17” Ripping

Chisel, Cold, 41276”

Chisel, Cold, 41463”

Reciprocating Saw

Air Blow Gun, Self-Relieving Safety-Type

Tape Measure, 25 ft

Magnetic Torpedo Level, 3-Vial Bubbles

Magnetic Weld Triangle

Combination Square, 16”

Carpenters Square, 16” By 24”

Triangle File, 8”

Wheel Chocks

Wire Brush

10-Way Wrench

Rod Oven Box- 10lbs Capacity

Anchor Chipping Hammer

Equipment

Drive Roll Kit, .035"

Drive Roll Kit, .045"

Hose, Gas

Hose Reel W/ 2/0 Cable - Ground Cable & Electrode

Hose Reel W/ 1/2" - Air, 50 ft

Hose Reel W/ 1/4" Twin Hose - Oxy Fuel Cutting, 50 ft

Hose Reel, 115v Aux Power, 50 ft

Hose Reel, 220v Aux Power, 50 ft

Hose Reel W/ 1/4" Hose , 300 Psi, 50 ft

Weld Cable Stinger Electrode Holder, 25 ft

Ground Cable W/ Clamp, 10 Ft Cable

Electrode Cable Extension, 50 ft

Air Hose, 1/2", 50 ft, Goodyear

4. VERIFICATION

4.1. Verification Information for the Contractor. Validation and verification shall occur in three phases:

The absence of any inspection requirements within this performance specification shall not relieve the contractor of the responsibility for ensuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Unless otherwise specified within the contract or performance specification, the contractor is responsible for the execution of all inspections and selected verifications as stated in this performance specification. The contractor is responsible for ensuring that components and materials are manufactured, inspected, and validated in accordance with referenced specifications and standards, as applicable. Failure to comply with any of the requirements in section 4.3 shall be cause for rejection.

4.1.1. Vendor Certification. The vendor shall certify the MCTWS is in conformance with the performance specification as outlined in section 4.3.

4.1.2. Government Verification. MCTWS that have met all inspection, verification, and certification requirements at the factory shall be shipped to a Government test site and subjected to validations and/or inspections as outlined in section 4.3. Validations shall be conducted using JP-8. MCTWS shall be subjected to the manufacturer's break-in procedure/duration prior to validation if required.

4.1.3. Production Unit Inspection.