ATC_PSPEC_-_FINAL_-_18_APR_2018.doc

PERFORMANCE SPECIFICATION FOR THE ALL TERRAIN CRANE (ATC) SERVICE LIFE EXTENSION PROGRAM (SLEP)

1. SCOPE

This specification defines the performance requirements that shall be maintained of the All-Terrain Crane (ATC) in its current configuration and additional requirements that shall be obtained upon the completion of the Service Life Extension Program (SLEP) efforts. The ATC is a rubber tired, hydraulic boom, all terrain crane capable of lifting and swinging 80,000 pounds. The ATC provides high speed, all terrain capability to lift extremely heavy loads, with high reliability; availability and maintainability. It is currently used to load/unload break bulk cargo from a fixed port or pier; on and off airfield runways; and over unprepared and uneven surfaces. The ATC is also driven on primary and secondary highways, to include sand, snow, and mud.

1.1 Refurbishment

The ATC SLEP intends to refurbish and improve the ATC to a like new condition through modification; inspection and component repair/replacement, followed inspection and validation. The ATC shall be returned back to the original configuration and maintain performance requirements of Section 3.

1.2 Improvements/Modifications (6):

The ATC shall incorporate the following improvements and modification to meet the performance requirements of Paragraph 3.

a) Develop a modification that protects the sheaves from crushing during placement in the stowage position and while setting up for travel. (See 3.11)

b) Develop a modification that relocates the Boom Locking Pin Stowage. The current configuration impedes access to battery box. (See 3.50)

c) Provide the newest compatible version of the Safe load indicator (SLI) that meets the specifications in the Performance Specification. (See 3.12)

d) Provide four (4) lightweight outrigger pads for each ATC and develop a user-friendly stowage location during transportation. (See 3.34 and 3.34.1)

e) Provide a fiber polyester, or synthetic 100,000lb sling solution that is ultraviolet (UV) protected and can be stowed on the ATC. (See 3.32.2)

f) Provide the updated instrument gage bundle in both cabs that still meets the requirements of this Performance Specification. (See 3.19) g) h) i) j) k)

2. APPLICABLE DOCUMENTS

2.1 General.

The documents listed in this section are specified in Sections 3, 4, or 5 of this Performance Specification. This section does not include documents that are referenced in other sections of this Performance Specification, recommended for additional information or examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in Sections 3, 4, or 5 of this Performance Specification, whether or not they are listed

2.2 Government Documents.

The following specifications, standards, and handbooks form a part of this document as specified herein. These documents may be listed in the Department of Defense Index of Specification and Standards (DoDISS) which indicates the latest version. If the revision is not specified, documents shall be the issue current on the date of the solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

FED-STD-595

Colors Used in Government Procurement Department of Defense

STANDARDS, Department of Defense

MIL-B-46176A

Brake Fluid, silicone, Automotive, All Weather, Operational and Preservative, Metric

MIL-C-53039D

Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

MIL-DTL-32361A

Composite Light, Tail Stop, Turn and Marker

MIL-DTL-53030D

Primer Coating, Epoxy, Water Based, Lead and Chromate Free

MIL-DTL-64159B

Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant

MIL-L-2104F

Lubricating Oil, Internal Combustion Engine

MIL-L-2105D

Lubricating Oil, Gear, Multipurpose

MIL-L-46167B

Lubricating Oil, Internal Combustion Engine, Arctic

MIL-PRF-11021H

Switch, Vehicular Lights: 28 Volt DC

MIL-PRF-14105E

Paint, Heat-Resisting (For Steel Surfaces)

MIL-PRF-10924H

Grease, Automotive and Artillery

MIL-PRF-81309G

Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film

MIL-STD-1179E

Lamp, Reflectors, and Associated Signaling Equipment for Military Vehicles

MIL-STD-129R

DoD Standard Practice for Military Marking

MIL-STD-130N

DoD Standard Practice U.S. Military Property, Identification Marking of U.S. Military Property

MIL-STD-1366E

Transportability Criteria

MIL-STD-1472G

Design Criteria Standard: Human Engineering

MIL-STD-1791C

Designing for Internal Aerial Delivery in Fixed Wing Aircraft

MIL-STD-209K

Lifting and Tiedown Provisions

MIL-STD-461G

Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and EquipmentMIL-STD-642L Identification Marking of Combat and Tactical Transport Vehicles

MIL-T-83133J

Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8) and NATO F-35

MS500004 Rev A Pad Eye, Vehicular-towing Lug

MS51318B

Headlight, Blackout, 24-Volt Waterproof

MS52126

Composite Light Front, Turn, Park and Marker

MS52131

Connector, Plug, Electrical Intervehicle Power Cable Unless otherwise indicated, copies of the above specifications, standards and handbooks are available either from the Government Printing Office or the Department of Defense Single Stock Point (DoDSSP) Subscription Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. The DoDSSP may be accessed through the Defense Automated Printing Service (DAPS) Philadelphia website (http:\\www.dodssp.daps.mil).

2.2.1 OTHER GOVERNMENT DOCUMENTS.

DEPARTMENT OF LABOR (DOL)

29CFR 1910

Occupational Safety and Health Standards (OSHA)

29CFR 1926

Safety and Health Regulations for Construction (OSHA)

DEPARTMENT OF TRANSPORTATION (DOT)

49CFR 393

DOT Federal Motor Carrier Safety Regulations (FMCSR)

49CFR 571

DOT Federal Motor Vehicle Safety Standards (FMVSS) Drawing K11630529 29 NOV 83 Rifle Mounting Kit M16/M14

2.3 NON-GOVERNMENT PUBLICATIONS. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B30.5 Mobile and Locomotive Cranes: Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings B56.6 Safety Standard for Rough Terrain Forklift Trucks (Applications for copies should be addressed to: Society Of Automotive Engineers, Inc, 400 Commonwealth Dr, Warrendale, PA 15096.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

Z26.1 Safety Glazing Materials for Glazing Motor Vehicles Operating on Land Highways

Z535.1 Safety Color Code Z535.3 Criteria for Safety Symbols Z535.4 Product Safety Signs and Labels (Applications for copies should be addressed to: American National Standards Institute, 1430 Broadway, New York, NY 10018.)

Boiler and Pressure Vessel Code, Section IX Qualification Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators.

ASSOCIATION OF AMERICAN RAILROADS (AAR)

General Rules Governing the Loading of Commodities on Open-Top Cars and Trailers

(Application for copies should be addressed to the IRF, 525 School St., Washington, D.C. 20024).

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A463 Steel Sheet, Cold Rolled, Long Term Coated

B308 Standard Specification for Aluminum

D3951 Standard Practice For Commercial Packaging G82 Standard Guide for Development and Use of a Galvanic Series for Predicting Galvanic Corrosion Performance.

(Application for a copy should be addressed to the ASTM, West Conshohocken, PA 19428-2859).

AMERICAN WELDING SOCIETY, INC. (AWS)

AWS D1.1

Structural Welding Code - Steel.

AWS D14.3

Earthmoving and Construction Equipment Welding, Section 5.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 3411

Earth-Moving Machinery – Physical Dimensions of Operator & Minimum Operator Space Envelope

ISO 3450

Earth-Moving Machinery – Wheeled or High-Speed Rubber-Tracked Machiners – Performance Requirement & Test Procedures for Brake Systems

ISO 3471

Earth-Moving Machinery – Roll-over Protective Structures – Laboratory Tests & Performance Requirements

POWER CRANE AND SHOVEL ASSOCIATION (PSCA)

Mobile Hydraulic Crane Standards (PCSA No. 4)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

(Application for copies should be addressed to: Society Of Automotive Engineers, Inc, 400 Commonwealth Dr, Warrendale PA 15096.)

TIRE AND RIM ASSOCIATION, INC. (TRA)

Tire and Rim Association Yearbook (Application for copies should be addressed to: Tire & Rim Ass Inc, 3200 W Market Street, Akron OH 44313.)

3. REQUIREMENTS

3.1 Operational Requirements.

The Service Life Extension Program efforts shall not degrade the operational performance of the legacy ATC. The ATC shall remain the manufacturer's standard commercial product meeting all applicable U.S. DOT, EPA requirements for highway travel and be capable of traveling on rough terrain. The ATC shall still follow normal crane industry practices for hydraulic cranes. The ATC shall still conform to ASME B56.6, SAE J98, and SAE J185 requirements and all standards list in Section 2 of this Performance Specification

3.2 Speed (On Paved Surfaces)

The crane, without load, shall remain capable of attaining and maintaining a travel speed of not less than 45 miles per hour (MPH) travel speed over paved surface.

3.3 Clamshell and Concrete Bucket Operation

The ATC SLEP shall maintain all components or accessories necessary to be connected and operate at full capacity a hydraulic clamshell and using the Marines Corps current concrete bucket.

3.3.1 The clamshell capacity shall remain 2.5 cubic yard (cu. yd.).

3.4 Physical Characteristics

The ATC shall meet the threshold physical characteristics requirements listed in Table 1.

Table 1. Physical Characteristics

3.5 Lift Capacity

The ATC shall maintain the lifting capacity of 80,000 pounds (lbs).

3.6 Ground Clearance

The ATC shall maintain a minimum ground clearance of 15 inches.

3.7 Fording

The ATC shall maintain an underwater fording capability up to 36 inches in salt water without the implementation of fording aids.

3.8 Boom Operation and Attachments

The SLEP ATC crane assembly should perform just as the legacy crane with a continuously revolving superstructure with boom support, hydraulically operated telescoping boom, attachments (when specified), main and auxiliary winch with wire rope, hook block, cab, controls and necessary accessories as specified in this document. The crane configuration shall permit connection and operation with the attachments specified with all hardware parts and components necessary to provide interface requirements for operation included. The design of the completely assembled crane should be such that the design strength margins will not be less than the minimum strength margins contained in SAE J1063. Tests, in accordance with SAE J1063 and J765, shall have been performed on the crane being provided or test results shall be made available for Government inspection at the time of tests.

3.9 Lifting Radius and Swing Capability

The crane shall maintain its ability to lift 80,000 lbs at a radius of 12 ft. Swing will be defined as 360-degree rotation at a speed of at least 1 revolutions per minute (rpm). The crane may be equipped with an audible warning device during cab rotation.

3.10 Boom, Winch, and Hoist

The ATC is equipped with a multi-section hydraulic, telescoping type boom consisting of a base section and sliding section(s). ATC SLEP shall maintain a retracted length no longer than 30 feet, and the total extended length of at least 80 feet. The boom shall be capable of elevation from the horizontal to a vertical angle of not less than 80 degrees. The crane shall be equipped with, but not be limited to, the following:

a. Variable speed hoist winch capable of providing sufficient line pull to support the maximum rated load and operate the attachments.

b. Sufficient wire rope to allow for concrete bucket and clamshell bucket operations.

c. Mechanical boom angle indicator.

d. Painted boom markings to indicate boom length.

e. Load hoist ropes in accordance with ANSI/ASME B30.5.

f. Sheaves provided in accordance with ANSI/ASME B30.5.

g. Adequate running block and hook weight to insure payout of cable without load on the hook.

h. Swivel type hook with a lockable safety latch.

3.11 Anti-Two-Block Lockout System

The ATC shall be equipped with an anti-two-block lockout system that functions while the SLI is in the travel mode, to avoid two-blocking and crushing of the sheaves during setup and stowing operations.

3.12 Safe Load Indication/Load Moment Indication

The crane shall be equipped with the latest compatible Safe Load Indicator (SLI) or Load Moment Indicating (LMI) system. Criteria specified in this document shall follow normal commercial industry practices for the SLI / LMI system. The SLI / LMI system shall use existing crane electrical power and shall operate within all climatic conditions specified in Paragraphs 3.1, 3.13, and 3.44. The SLI / LMI system shall meet the recommended requirements specified in SAE J159. The SLI / LMI system shall consist of, but not be limited to, the following:

a. Anti-two block hoist limit system

b. Load Moment Indicating system

c. Boom length indicator feature

d. Boom angle indicator

e. Boom radius indicator

f. Provide actual weight

g. Must warn of overload condition and provide a hydraulic look out, with emergency over ride.

h. Provide parts of line

i. Must operate in cab climatic conditions up to 140° F

j. Cab mounted operator display console, must be backlit and have adjustable contrast

3.13 Tires

The crane shall be equipped with multipurpose, all traction tread, tubeless radial or biases ply tires. Tire and rim ratings shall conform to the standards set forth in the TRA Yearbook, for the appropriate type of tire and be equipped with no less than 16 ply-rated, pneumatic tires that provide sufficient traction and flotation to enable the crane to operate in the various beach conditions found throughout the world, and on the Elevated Causeway System.

3.14 Approach, Departure, and Cross Slope Angles

The ATC SLEP shall maintain the capability of negotiating both an angle of approach and an angle of departure of at least 20 percent (11.3°), negotiating the ramp of a landing craft at a longitudinal slope of at least 45 percent (24.2°) in both forward and reverse gears, at a speed of not less than 1.5 mph, and of negotiating at least a 20 percent (11.3°) cross slope.

3.15 Brakes System

The ATC SLEP shall maintain the capability of stopping and then accelerating while ascending and descending a 45 percent (24.2°) longitudinal slope while in both forward and reverse gears. Service disc brakes must be capable of stopping and holding the crane on a 45 percent (24.2°) slope. The parking brake must restrain the crane on at least a 20 percent (11.3°) longitudinal slope and meet the requirements of ASME B56.6, ISO 3450, SAE J1152 and SAE J 1977.

3.16 Rough Terrain Capability

The ATC SLEP shall maintain the capability of traversing uneven and unprepared surfaces (rough terrain to include sand, snow, and mud) and of fording at least 36 inches of salt water, including wave action without fording kit.

3.17 Turning Radius

The ATC SLEP shall maintain the capability of executing a 360-degree turn within a maximum curb-clearance circle of 60 feet.

3.18 Steering Modes

The ATC SLEP shall maintain front-wheel, all-wheel, and crab steering modes. An in-the-cab indicator shall show, at a glance, the steering position of the rear wheels. The emergency steering system, secondary steering system, or a comparable capability conforming to SAE J1511, , SAE J898, and SAE J695 shall be maintained on the ATC SLEP.

3.19 Operators Cab

The ATC SLEP shall maintain with an environmental controlled, enclosed cab to enhance operator performance in extreme climates in accordance with ISO 3411. The cab or cabs should consist of, but not be limited to, the following:

a. A complete ROPS and FOPS structure conforming to ISO 3471, SAE J397, and SAE J1119.

b. A seatbelt conforming to SAE J386 Type I shall be included in the design.

c. The operator’s seat shall be furnished in accordance with minimum requirements of SAE J899, and be located to permit full mission performance.

d. The cab must be of sufficient size to permit full mission performance by personnel (5 percent female to 95 percent male percentile) wearing the complete Nuclear and Biological and Chemical (NBC) contamination Mission Oriented Protective Posture (MOPP) IV protective ensemble (MOPP IV), the environment protective clothing, or body armor conforming to SAE J833.

e. Should be equipped with a single speed in cab electric fan.

f. The cab doors must be capable of being secured/latched in the open position.

g. Cab glass shall allow for secondary ventilation and escape (nonelectric windows). Safety glazing should be provided for all windows in conforming to ANSI Z26.1.

h. The windshield and the rear window shall be equipped with at least one wiper/washer assembly in accordance with SAE J198 and SAE J942 respectively.

i. Cab access, steps, handholds and ladders conforming to SAE J185.

j. All driving controls’ symbolic markings should be in accordance with SAE J1362. All controls for the crane located in the operator’s compartment should be within the maximum area specified in SAE J297 and SAE J898.

k. Be furnished with a heater/defroster in accordance with SAE J1503 and SAE J1535.

l. A cab-mounted rifle rack is required to secure the operators weapon. The rack conforming to drawing number 13229E8014 shall be mounted by the contractor in a location inside the cab mounted within arm’s reach of the operator, however provides clearance for the rifle to be removed. The bracket location should not obstruct the vision of the operator.

m. The air conditioner should be capable to operate in the cooling mode at ambient temperatures between 650F and 1250F and should meet the cooling requirements of SAE J1503. The air conditioning system should be equipped with the following service ports: discharge, suction, and recovery. The refrigerant, if used with any kit, may be R-134a, and all materials in the system are compatible with R-134a and ester lubricants.

n. The cab shall be equipped with an updated load chart for the ATC for 100,000 lb synthetic slings

3.20 Corrosion Resistance

The ATC SLEP shall maintain its resistance to corrosion during unprotected storage and from the effects of a salt-water environment.

3.21 Operating Conditions

The ATC SLEP shall remain capable of starting and operating, and meet the operational, logistical, and readiness requirements in all types of climatic, weather, and illumination conditions.

3.21.1Low Temperature Operation

The ATC SLEP shall remain capable of starting and operating in ambient temperatures down to –250F.

3.21.2 High Temperature Operation

The ATC SLEP shall remain capable of starting and operating in ambient temperature up to +1250F.

3.21.3 Rain Operation

The ATC SLEP shall remain capable of starting and operating in rainfall up to four inches per hour.

3.21.4 Blowing Dust and Sand

The crane shall start and operate in environments where there is blowing sand and dust particles.

3.21.5 Salt Fog

The crane shall remain resistant to the corrosive effects of a severe marine atmospheric environment consisting of seawater splash and spray, and occasional seawater immersion during operation, transport, and storage. The design shall use the guidance in the American Society for Testing and Materials (ASTM) G82 to determine materials compatibility. The crane shall be capable of operation in an environment where there is a 5% +/- 1% concentration of salt fog.

3.22 Electrical System

The ATC SLEP shall remain equipped with a 24-volt negative-ground electrical system with a 24 volt alternator, 24 volt starter and battery equalizer. Electrical wiring should be in accordance with SAE J 821.

3.22.1 NATO Slave

An external 24-volt NATO standard electrical slave receptacle conforming to MS52131is required.

3.22.2 Battery System

Installed batteries should have sufficient cold cranking amperage to start the crane at –25° F. The following equipment shall be installed on the crane:

a. Pulse-Tech 24 volts Solargizer PN# 735X160, National Stock Number (NSN) 6130-01-396-2166

b. New Hawker ARMSAFE Plus Batteries NSN: 6140-01-485-1472 in sufficient numbers to support the system.

c. Battery cables with insulated covers shall conform to SAE J1127.

3.23 Blackout Lighting

The ATC SLEP shall remain capable of providing adequate operator-adjustable lighting for night operations in accordance with MIL-DTL-32361, MS51318, MS52126, SAE J1029, SAE J586, and SAE J594. The crane shall be equipped with a blackout lighting system, to include at least:

a. A single forward illumination capability.

b. Two blackout stoplight-taillights mounted in the rear.

c. Indicator lights shall be operable in blackout mode.

d. Additional lighting, conforming to the aforementioned standards, in the interest of safety of operation for the crane, is encouraged.

3.24 Diagnostic Connector Assembly

The ATC SLEP shall incorporate the commercial standard capability for fault identification and diagnostics or Diagnostic Connector Assembly (DCA). The crane shall incorporate an easily accessible DCA in the operator's cab for interface with the Government’s Vehicle Automated Diagnostic System (VADS). Data will be transmitted to the VADS via a serial data network in accordance with SAE J1708 and SAE J1587 and as coordinated with the manufacturer.

3.25 Transmission

The ATC SLEP shall remain equipped with the commercial power shift, automatic transmission, or equivalent and may be equipped with transmission disconnect feature. All Wheel Drive is required. The crane, without load, shall be capable of attaining and maintaining a travel speed of not less than 45 miles per hour (MPH) on primary roads. Use of military standard transmission oil conforming to MIL-L-2105 and an accessible oil-sampling valve is desired.

3.26 Engine

The ATC SLEP shall remain equipped with a diesel engine that is not degraded from original specifications, including all systems and accessories. The engine shall conform to the year of manufacture for EPA diesel engine emission standards for Tier III requirements.

a. The required operation fuels include: diesel fuel oil; aviation kerosene type turbine fuel grade JP-5 / JP-8 / F-24 and must run for 10-hours of continuous craning.

b. The engine shall be capable of operating with standard military petroleum, oil and lubricants (POL) conforming to MIL-L-2104.

c. An accessible oil-sampling valve is desired.

d. The engine shall remain equipped with an on-board engine-driven air compressor for the inflating of pneumatic tires. The air compressor must be capable of inflating one (1) crane tire in 25 min or less.

3.27 Fuel Tank

The ATC SLEP shall remain equipped with a fuel tank filler neck sized to accept a fuel nozzle of minimum 3-inch diameter with removable screen.

3.27.1 Fuel Tank Drain

The ATC SLEP fuel tank drain petcock valve shall remain located at the lowest point of the tank.

3.27.2 Fuel Tank Shut Off Valve

The crane shall have fuel shut off valves on both suction and return lines.

3.28 Axles

The ATC SLEP shall not degrade the axles’ ability to oscillate at least 10 degrees above and below the horizontal axle centerline that can be hydraulically locked to the frame to prevent oscillation

3.29 Human Factors Engineering

The ATC SLEP shall meet applicable DoD human engineering, health, and safety standards and employ user-friendly features for personnel operating in or near the crane throughout the service life.

3.30 Chemical Decontamination

The ATC SLEP shall remain capable of operating after exposure to chemical decontamination solutions, and shall incorporate seals and other synthetic components that are resistant to deteriorating bacteria. Nuclear survivability is not required.

3.31Attachment Operation and Setup

The ATC SLEP shall not degrade the crane’s capability to change from the crane configuration to either the concrete bucket, or clamshell bucket configuration in less than two hours. Attachments must be operated at a radius of at least 25 feet with the crane on outriggers.

3.32 Slings

The ATC SLEP shall be equipped with commercial standard four leg adjustable slings, with a load lifting capability equal to that of the crane. The sling must be of sufficient size to lift vehicles organic to the Marine Corps and odd shaped vehicles. The crane must be capable of stowing slings in a securable compartment on the crane during transportation.

3.32.1 Legacy Slings

The ATC SLEP shall maintain the existing sling capabilities

3.32.2 Fiber, Polyester, or Synthetic Slings

The ATC SLEP shall be equipped with UV protected fiber, polyester, or synthetic slings capable of lifting 100k lbs.

3.33 Spreader Bars/Tandem Loc System

The ATC SLEP shall remain outfitted with Tandem Loc system to handle organic Marine Corps assets and remain stowed on the crane during transportation.

3.34 Outrigger Pads

The ATC SLEP shall be equipped with four (4) outrigger pads capable of being stored onboard during transportation.

3.34.1 The Outrigger Pads shall be stored and secured on the ATC in a location that does not degrade the operation of the crane.

3.35 Packaging, Identification and Marking.

The ATC SLEP shall meet all packaging, identification and marking found in section D of the contract.

3.36 Maintainability.

The crane must be easily maintained. The ATC SLEP design shall be such that maintenance and repair can continue to be executed with common tools. No unusual mechanical skill shall be required at any level of maintenance. The SLEP shall not degrade the provisions for servicing and replacement of all parts and components. All access openings shall be in compliance with commercial practices and SAE J925. None of the following factors shall degraded by the result of the SLEP.

3.36.1 Daily Operator Inspection

A daily operator functional inspection developed by the manufacturer shall take no more than 10-minutes.

3.36.2 Preventative Maintenance

Preventive maintenance (PM) procedures associated with the design and desired operational intent of the crane shall be defined.

3.36.2.1 Scheduled preventive maintenance (except for operational checks) shall not be required more often than every 50 hours. Before/during/after operational checks will be conducted in accordance with the technical manuals.

3.36.3 Corrective Maintenance

Corrective maintenance (CM), which includes the adjustment, removal, repair, reinstallation and alignment of repairable parts, modules, subassemblies, and assemblies, shall be defined. The ATC SLEP shall not require use of unique, peculiar, or proprietary support equipment, tools, or other devices to support the crane. The Common Support Equipment (CSE) and Peculiar Support Equipment (PSE) already identified for the legacy crane, necessary for operation and support, are excluded.

3.36.4 Mean Time to Repair (MTTR) of less than 4 hours, with an objective of 2 hours, is desired.

3.36.4.1 CM actions involving complete repair, disassembly and reassembly of major subassemblies (engines, axles and transmissions) are desired to be performed within an MTTR of 12-hours, or less.

3.37 Mission Reliability

Mission reliability is defined as the probability that the crane shall function properly when correctly employed by the user. The ATC SLEP shall maintain a Mean Time Between Operational Mission Failures/Mean Time Between Failure (MTBOMF/MTBF) 75 hrs, with a confidence level of 85 percent and with no more than a .10 maintenance ratio (MR) based upon a 1000-hour annual operational scenario. A failure is defined as malfunction, breakage or stoppage that prevents the machine from performing its intended mission (moving or lifting materials) that cannot be corrected by the operator within 20 minutes.

3.38 Equipment Availability

The crane shall be capable of completing at least 1000 hours of operation before replacement or rebuild of major components, such as the engine, transmission, power train, and hydraulic system is required.

3.39 Electromagnetic Interference

The crane, to include all operator controlled components except horn and windshield wiper pump, shall not be degraded from the accepted characteristics of the legacy system.

3.40 Manpower Requirements

The crane shall be maintained by engineer equipment mechanics (MOS 1341) within the existing maintenance structure for engineer material handling equipment. The crane shall continue to be operated by engineer equipment operators (MOS 1345) within the existing Marine Corps manpower/force structure.

3.41 Operational Range

The crane shall have an operating range of 31 miles on improved and unimproved surfaces. The crane shall be capable of being transported worldwide without disassembly via commercial rail, marine, highway and air.

3.42 Rail Transportability

The crane shall be rail transportable in CONUS and NATO countries without restrictions. When loaded on a 50-inch (127-cm) high rail car, the crane should have a dimensional profile within the Association of American Railroads (AAR) outline diagram and the Gabarit International de Chargement (GIC) as specified in MIL-STD-1366. The crane shall withstand the shock loads resulting from rail impact testing in accordance with MIL-STD-209 without breaking free, loosening, or showing any sign of permanent deformation.

3.43 Marine Transportability

The crane shall be marine transportable in accordance with MIL-STD-1366 and withstand, without damage, the shock, rolling (not to exceed 15o), and pitching (not to exceed 10o) normally experienced on the deck or in the hold of a cargo vessel. The crane shall be capable of being embarked and disembarked, without disassembly, from all roll-on/roll-off (RO/RO) and amphibious classes of ships. It is desired that it be capable, under its own power, of embarking/disembarking through the surf.

3.44 Highway Transportability

The crane shall be capable of unrestricted highway transport using current military and commercial trailers on all state/federal and appropriated foreign highways. Should the crane become disabled through engine failure, it should be capable of being towed. The transmission should be able to disengage from the wheels for towing by one man using appropriate devices and tools. The desired timeframe to accomplish this action is less than one hour.

3.45 Air Transportability

The crane shall meet the minimum requirements of MIL-STD-1791 for C-17, and C-5 air transport. The crane shall be capable of being driven on and off both aircraft in the hook block operational configuration.

3.46 Slinging And Tie down Provisions

The slinging and tie down provisions shall conform to MIL-STD-209 and to MIL-STD-1791 for equipment restraint criteria. The crane shall satisfactorily complete the testing as specified in MIL-STD-209. The provisions shall enable the complete crane to be lifted in the normal operating position. All slinging and tie down points shall be labeled “LIFT”, “TIEDOWN”, or “LIFT/TIEDOWN”, as applicable, in one-inch high letters.

3.47 Towing Pintle

The ATC SLEP shall remain equipped with front and rear towing pintles, conforming to MIL-STD-209.

3.48 Recoverability

The crane shall remain recoverable with organic Marine Corps assets.

3.49 Material

Material selection, paint finishes and processes shall avoid use of toxic chemicals, hazardous substances and ozone depleting chemicals for vehicle production, maintenance, repair, operation, shipping, handling and reclamation. All parts having the same manufacturer’s part number shall be interchangeable.

3.49.1 Treatment and Painting

Unless otherwise specified, all coated surfaces on the modified portions of the ATC, 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 top coated

3.49.2 Exterior Panels

Exterior panels shall be free of imperfections. Dents shall not be larger than 3” x 3” area. There shall be no holes or cracks present in the panels.

3.50 Boom Locking Pin/Battery Storage Box

The Boom Locking Pin shall be relocated to allow for the opening of the Battery Storage Box in its locking position. The new position shall allow for the same locking capabilities as the legacy pin location.

4. VERIFICATION.

4.1 General

The ATC SLEP compliance with the requirements listed in Section 3 shall be verified using the methods established in Section 4. Refer to Table 3 for a summary of the verification method.

4.2 Methods of Verification

This performance specification will require verification if the SLEP efforts requires more than a corrective or preventative maintenance activity that alters the configuration of the legacy crane. The manufacturer, prior to shipment of the crane, shall perform quality assurance inspections and provide appropriate certifications of compliance with the specification. Compliance with the requirements listed in Section 3 shall be verified using one of the methods listed below.

4.2.1 Analysis (A). Analyses shall be conducted by the Contractor as specified herein or the Government utilizing established technical or mathematical models or simulations, algorithms, charts, graphs, circuit diagrams, or other scientific principals and procedures.

4.2.2 Demonstration (D). Demonstrations shall be conducted by the Contractor as specified herein; or the Government at a Government-designated test agency involving the actual operation of the system to provide evidence that the required functions were accomplished under specific scenarios. The system may be instrumented and performance monitored.

4.2.2.1 Paragraphs 3.19 Operators Cab and Paragraph 3.29 Human Factors Engineering will be assessed by the government to evaluate effectiveness of the updates made to the cab and instrument panel. User survey feedback during the User Evaluation will also be reviewed and assessed.

4.2.2.2 Paragraph 3.34 Outrigger Pads will be evaluated by the government during a user evaluation to determine the effectiveness of the storage location and process to deploy and store the pads. The effectiveness of the storage design will be assessed during transport and driving of ATC. User survey feedback will be reviewed and assessed.

4.2.3 Inspection (I). Inspections shall be conducted by the Contractor as specified herein; or by the Government at a Government-designated test agency or by a Quality Assurance Representative (QAR) at the Contractor's facility utilizing sight, hearing, smell, or touch; simple physical manipulation; and mechanical and electrical gauging and measurement.

4.2.4 Test (T). Tests shall be conducted by the Contractor as specified herein; or by the Government at a Government-designated test agency applying scientific principles and procedures to determine the properties or functional capabilities of the system.

4.2.4.1 Paragraphs 3.11 Anti-Two-Block System, Paragraph 3.12 SLI/LMI, and Paragraph 3.32.2 will be tested by lifting at least 100,000 lbs for a minimum of 10 minutes. Load center will be at a maximum distance of 12 ft radius.

4.3 Responsibility for compliance

The absence of any verification method within this performance specification shall not relieve the contractor of the responsibility for acceptance and compliance. Unless otherwise specified within the contract or performance specification, the contractor is responsible for the execution of all inspections and certifications as stated in this performance specification. The contractor is responsible for ensuring that components and materials are manufactured, inspected, and tested in accordance with referenced specifications and standards, as applicable. Failure to comply with any of the requirements shall be cause for rejection.

4.4 Conformance inspections/tests

A crane that has met all inspections, test, and certification requirements at the factory, shall be shipped to a government site. The government reserves the right to validate requirement conformance through independent analyses, inspections and/or testing. Crane deficiencies found as a result of testing/inspection shall be a cause for rejection until the manufacturer has provided evidence that corrective action has been taken to eliminate the deficiency. The manufacturer, at no additional cost to the government, shall correct such deficiencies on all cranes.

4.5 Contractor Certifications

The contractor shall provide independent certification that the crane complies with all specific operating, operating environment, interface, ownership, and support requirements stated within this performance specification.

Table 2 Tests and Inspection Schedule

5 PACKAGING

5.1 The packaging requirements shall be as specified in the contract.

6. NOTES

6.1 Intended Use

. The crane will be used by engineer units to execute a variety of mobility, counter-mobility and survivability missions. The crane has utility in all combat environments. The crane will support missions requiring digging, lifting, and loading, logistics-over-the-shore and perform other tasks to include the repair, maintenance, and construction of survivability positions, roads, airfields, helipads, bridges, seaports, logistic bases, medical facilities, C2 protective shelters, structures and facilities. The crane will be utilized to support construction tasks, as well as loading and unloading, supplies, and equipment. It will be used to load/unload break bulk cargo from a fixed port or pier; on and off airfield runways; and over unprepared and uneven surfaces. It must also be capable of being driven over primary and secondary highways, to include sand, snow, and mud. It will also provide construction and logistic base support that will enhance the engineer support throughout the theater of operations. When equipped with various attachments, the crane can provide combat deployed units a host of mobility, counter-mobility, and survivability capabilities. The crane will be operated in peacetime in a manner similar to the conditions under wartime provisions. The crane will lift the commercial and military containers weighing up to 53,000 pounds. The crane will provide the container lifting and handling capability to support Sustained Land Operations (SOL) of the Landing Support Battalions (LSB), Combat Logistics Companies (CLCs) and Combat Logistics Battalions (CLBs). It will have the capability to load and unload cargo, from tactical vehicles, Maritime shipping, commercial shipping and have the ability to clear and move cargo from marshalling and staging areas. Employed by the Engineer Support Battalions (ESBs). In these units the crane will provide obstacle reduction, survivability (digging in critical positions) and sustainment capability. Its inherent mobility allows the maneuver command to send this piece of equipment on any mission. Employed by the Marine Wing Support Squadrons (MWSSs). In these units the crane will operate in support of the Air Combat Element. The crane capability will enhance the survivability effort, as well as, provide enhanced support.

6.1.1 Missions. The crane, with its attachments, will perform the following missions in support of the various organizations above:

a. Mobility.

(1) Obstacle reduction.

(2) Construct, opening, clearing, and maintaining roads.

b. Counter-mobility.

(1) Obstacle emplacement.

(2) Obstacle integration.

c. Sustainment.

(1) Construct and Maintain Roads and highways.

(2) Construct and Maintain Over-the-Shore Facilities.

(3) Construct and Expand Airfield Facilities.

(4) Load and unload cargo.

(5) Provide Engineer Construction Support.

6.1.2Operational Environment.

a. Visibility. Under high intensity usage conditions it is projected that over 50 percent of operations will be conducted in limited visibility (darkness, fog, haze, rain, smoke and other artificial obscurants). In normal conditions 25 percent or less of operations will be conducted in limited visibility.

b. Movement.

Table 3

c. Climatic design.

Table 4

6.1.3Mission Profile.

a. The ESBs, and MWSSs units have similar requirements for the crane. Tables 5 and 6 show a functional display of it use, and where it is expected to perform in training and/or tactical situations.

Table 5

HIGH INTENSITY USE (72 HOUR)

Table 6

NORMAL OPERATION (24 HOUR)

b. The crane will be deployed, to execute mobility tasks, excavation and construction support missions. The missions are expected to range from light lifting and loading of material and logistics. In addition the crane will perform general engineering construction, in support of Division, Marine Logistics Group , and Air Wing, as well as theater military operations.

c. Over a thirty- (30) day period high intensity usage would take place once. The remainder of the time is considered normal usage operation.

d. Table 7 shows the attachment usage for the crane.

Table 7

ATTACHMENT USAGE

6.2 Definitons.

Failure. A failure is the malfunction of any single component that will prevent the system from performing as specified in this document.

Interchangeability. Interchangeability applies to items and components that are capable of being readily installed, removed or replaced without alteration, misalignment or damage to items or components being install or to adjoining items or structure.

Government. Any reference to government applies to the United States Government only.

Performance Objective. The performance objective value is that desired by the government. The objective value represents an operationally meaningful increment of performance value.

Performance Threshold. The performance threshold value is the minimum acceptable value required by the government.

“Provisions For”. “Provisions for” includes “SPACE PROVISION”, “WEIGHT PROVISION” and “POWER PROVISION”; and means that complete installation provisions, including all necessary supports brackets, wiring, tubing, connectors, interconnecting cables, fittings, etc. will be provided for securing the item or equipment in place, ready for operation, without further alterations or additional fabrication of parts. Associated fastenings such as nuts and bolts for the item or equipment are not included. The item or equipment, including its provisions, will be included in the weight empty, unless specifically stated to be mission load or special equipment.

Support Equipment/Equipment. All equipment required to make a system operational in its intended environment. Excluded are:

a. Common powered and non-powered hand tools.

b. Housekeeping items.

c. Common production tools and tooling such as lathes, drill presses, etc.

d. Items used only by the contractor.

e. Personal equipment (headsets, microphones, etc.).

f. Off-line automatic data processing (ADP) equipment.

Common Support Equipment (CSE). CSE is equipment designed for a wide range of support applications and currently exists in the using service’s inventory.

Contractor Furnished Equipment (CFE). CFE is contractor unique equipment designated for the support and testing of a specific item or equipment facility.

Government Furnished Equipment (GFE). GFE is existing equipment, presently utilized by the government, designated for the support and testing of a specific item or equipment family.

Peculiar Support Equipment (PSE). PSE is unique equipment designated for support and testing of a specific item or equipment family.

Use of Should, May, Shall, and Will. “Should” and “May” are used whenever it is necessary to express non-mandatory but desirable provisions. “Shall” and “Will” are used whenever it is necessary to express mandatory provisions.

Analysis. Analysis is a study of data and is used to verify that an item or function meets specified requirements, or portions thereof. Analysis data may contain derived analytical data from mathematical expressions, and/or technical evaluation of existing data from related tests, observation or accepted source documents.

Demonstration. Demonstration is a variation of test used to verify performance without the use of elaborate equipment. Operation of a unit in or near its use-environment would be defined as a “demonstration” rather than a “test.” Demonstration involves operation, movement (including necessary adjustment) of the item in performing its design functions, under a specific set of conditions without recording of quantitative data.