J1_First_Article_Testing.pdf

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NAVSUP WSS TE-1374

25 October 2018

Supercedes NAVSUP WSS TE-1374

15 June 2018

TEST AND EVALUATION REQUIREMENTS

TRUCK, FORKLIFT, COUNTERBALANCE, STAND-UP RIDER ELECTRIC, MARINIZED

1. First article testing (FAT). FAT shall be performed on fully operational, complete and production ready forklift truck(s), hereinafter referred to as truck. This document shall be used in conjunction with the Statement of Work and shall include the inspections, demonstrations and tests identified in Table I of this document.

2. Production quality conformance testing. All production trucks shall be subjected to the production performance tests marked “T” “I” or “D” in column 2 of Table I below.

3. Test terms and conditions. Test conditions and schedule shall be as follows:

3.1 Environmental conditions. Unless otherwise specified, tests shall be conducted at ambient temperature and climatic conditions existing at the place of test. Ambient conditions shall be recorded prior to each test.

3.2 Surface conditions. The test surface, unless specified within the tests procedures, shall be paved and level within +/- 1 degree. The surface of the test area shall be dry and free of debris, loose sand, gravel, etc. and be capable of producing a coefficient of friction of 0.5 or greater.

3.3 Truck operating temperature. Prior to any FAT requiring the operation of the truck and unless specifically prohibited within the testing procedure, the contractor may elect to operate the truck for a period of time to bring it to normal operating temperature.

3.4 Authorized maintenance. Only maintenance submitted prior to commencement of testing and designated by the manufacturer as scheduled routine maintenance, shall be performed during FAT.

3.5 Test Priority. Tests shall be in accordance with Table I and may be conducted in any order desired with the following exceptions:

3.5.1 Lift and tiedown testing shall be successfully completed prior to conducting HI-Shock testing.

3.5.2 Reliability shall be the last FAT initiated and completed.

3.5.3 Production and Production Quality Conformance testing shall not be initiated until the completion and Navy acceptance of all FAT results.

3.5.4 Documentation of UL safety rating compliance as noted in paragraphs 3.1.1 and 4.3.9 herein shall be provided for inspection prior to beginning of FAT. It is recommended that this be included as part of the FAT test plan (see paragraph 3.7.1 below).

3.6 Test Loads. All loads necessary to perform the testing/certification required by this document shall be an unrestrained cube with overall dimensions of twice the load center dimension and whose center of gravity is located at the geometric center of the cube. The tolerance for weight shall be +/- 1 percent.653

3.7 Tests, inspections and demonstrations. The unit(s) under test (UUT) shall be subjected to the tests, inspections and demonstrations marked by either "T", “I” or “D”, respectively, in Column 1 of Table I. Successful completion of all FAT tasks shall not exclude the remaining production trucks from the identified quality conformance testing.

3.7.1 FAT Plan. Prior to start of any FAT testing, inspections and demonstrations, the contractor shall submit a formal and detailed compilation of all test procedures to be used during each test, inspection and demonstration required herein. Accompanying this test plan shall be the anticipated test schedule detailing start and completion dates for each tests. This test plan and schedule shall be submitted for Navy review and approval not later than 30 days prior to the initial start date of the first FAT event and shall be updated and promptly provided to the Navy whenever any changes to the schedule become known. Details of test procedures shall include, but are not limited to: identification of all applicable documents, test requirements, definition of failures, detailed step-by-step description of testing, test set-up, related test equipment, facilities and unit preparations, pre and post-test inspections and evaluation methods. Separate H.I. Shock and EMI (MIL-STD-461) test plans shall be submitted as detailed in paragraphs 4.21.1 and 4.25.3.

CDRL A011 (FIRST ARTICLE TEST (FAT) PLAN) applies.

3.7.2 FAT Final Report. Upon completion of all testing the contractor shall compile all relevant FAT information into a final report. This report shall summarize all the results from the FAT program. This should include at a minimum, the original test plan and identify if testing had deviated from this plan and why, all test results, details on any failures, discrepancies, non-conformances during testing, listing of personnel witnessing testing and a description why testing is being recommended for approval. This test report shall be submitted for government approval within 30 days after completion of FAT. CDRL

A013 (FIRST ARTICLE TEST (FAT) FINAL REPORT) applies.

4. First Article Testing

4.1 Tire size, tire loading and deck loading. Test the truck in accordance with Test Method No.

1. Failure to conform to the requirements listed in Table I herein shall constitute failure of this test. Although there are no specific criteria for deck loading in STATEMENT OF WORK, it shall be determined and recorded during this FAT for future Navy reference.

4.2 Lifting and tiedown attachments. Test the truck in accordance with the tests indicated in MIL-STD-209. Failure to conform to the requirements listed in Table I herein shall constitute failure of this test.

4.3 Carriage Sideshift. Measure sideshift of carriage both with and without the rated load.

Failure to conform to the requirements paragraphs listed in Table I herein shall constitute

4.4 Battery protector. Test the truck in accordance with Test Method No. 2. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute failure of this test.

TABLE I. TEST, INSPECTION & DEMONSTRATION STRATEGY

First

Article

Production

Quality

Conformance

Test Test

Para.

Requirement

Paragraph *

Test

No.

T, I Tire Size & Tire Loading

4.1 3.14 1

T Lifting & Tiedown Provisions

4.2 3.16

T Carriage Sideshift 4.3 3.10

T Battery Protector 4.4 3.15.6 2

T T Lift & Lowering Speeds

4.5 Table I – Salient

Characteristics

T Outside Turning Radius

4.6 Table I – Salient

T T Travel Speed 4.7 3.19

T T Slope Ascension, Under clearance, Travel Disconnect & Parking Brake

4.8

4.14

3.20 3.22 3.12 3.13 3.27

T

Shipboard Ramp

Traverse

4.9

3.34

TABLE I. TEST, INSPECTION & DEMONSTRATION STRATEGY (CONTINUED)

First

Article

Production

Quality

Conformance

Test Test

Para.

Requirement

Paragraph *

Test

No.

I, D, T Forks, Fork Position & Fork Tilt

4.10 Table I – Salient

Characteristics

3.9 3.21

T Lift, Mast and Free Lift Height

4.11 Table I – Salient

T Lift Assembly Drift 4.12 3.23 5

T T Structural Load 4.13 3.18 6

T Stability 4.15 3.24

T Acceleration 4.16 3.25

I,D,T D

Service Brake & Regenerative

Braking Performance

4.17 3.11 3.26

T Resistance to Saline Atmosphere

4.18 3.28

T Power Consumption 4.19 3.29 7

T H.I. Shock Test 4.20 3.30 3.30.1

T Rain 4.21 3.32

First

Article

Production

Quality

Conformance

Test Test

Para.

Requirement

Paragraph *

Test

No.

T Truck Length, Width, Collapsed and Height

4.22 Table I – Salient

T Reliability 4.23 3.33 8

T Electromagnetic Interference

Susceptibility and Vulnerability

4.24 3.31 3.31.1

T Temperature 4.27 3.41

I, D I Diagnostics 4.26 4.26.1

3.40.1 (Incl. all sub para)

I, D, T Battery, Connectors & Compartment

4.28 3.4 3.5 3.6

I, D Hydraulics, Cylinders and hoses

4.29 3.7 3.7.1 3.7.2 3.7.3

I Lubricants and hydraulic fluids

4.30 3.8

I Operator’s Compartment & Control

Panel

4.31 3.15

3.15.1 3.15.2

D Master switch 4.32 3.15.3

I, D Hour-meter 4.33 3.15.4

First

Article

Production

Quality

Conformance

Test Test

Para.

Requirement

Paragraph *

Test

No.

I, D Warning Device/Horn 4.34 3.15.5

I, D Work Lights 4.35 3.17

I I Treatment, painting, non-slip coating, cadmium plating

4.36 3.35 3.35.1 3.35.2

I I Informational plates 4.37 3.36

I I Body and vehicle markings

4.38 3.37 3.38

I UL Safety Rating 4.39 3.3.1

Requirements paragraphs are found in Statement of Work.

4.5 Lift and lowering speeds. Test the truck by operating the fork lifting and lowering system at maximum speed both with and without the rated load. The timed distance traveled by forks shall be at least 90 percent of the maximum lift height. Repeat this test for at least a total of three events in both the lift and lowering function for both loaded and unloaded configurations.

The average of these runs shall be the value used to determine if the truck conforms to the requirements listed in Table I. Any non-conformance shall constitute failure of this test.

4.6 Outside turning radius. Test the truck and measure the outside turning radius. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute a failure of this test.

4.7 Travel Speed. Test the truck in both forward and reverse modes to determine maximum travel speed. Use a timed area of at least 44 feet. One cycle shall consist of the truck traveling through the timed area in both directions. This cycle shall be repeated three times each in forward and reverse travel modes as well as both with and without the rated load (a total of 12 cycles). Use the average travel speed from the three cycles of each configuration to determine if the requirements in table 1 have been met. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute failure of this test.

4.8 Slope ascension and under clearance. Test the truck in accordance with Test Method No.

3. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute

4.9 Shipboard ramp traverse. Test the truck in accordance with Test Method No. 4. Other than the wheels, any forklift contact with the ramp shall constitute failure of the test.

4.10 Forks, Fork spacing & Fork Tilt. Inspect the forks to verify that they are the correct size and taper. Verify that top surface has a nonskid surface. Position forks at their minimum separation and measure the distance between their outside edges. While lifting the rated load measure forward and rearward fork tilt. Failure to conform to the requirements listed in Table I herein shall constitute failure of this test.

4.11 Overall truck height, maximum fork height, mast height, free lift height. Measure overall truck height, maximum fork height, mast height (collapsed and extended) and free lift height. Failure to conform to the requirements listed in Table I herein shall constitute

4.12 Lift Assembly Drift. Test the truck in accordance with Test Method No. 5. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute failure of this test.

4.13 Structural Overload. Test the truck in accordance with Test Method No. 6. Quality conformance test shall be at 150 percent of rated load. First Article Proof test shall be at 300 percent of rated load. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute failure of this test.

4.14 Parking brake and travel disconnect. Test the parking brake in accordance with applicable steps of Test Method No. 3. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute failure of this test.

4.15 Stability. Test the truck in accordance with ANSI/ITSDF B56.1 using the slopes defined in the requirements paragraph listed in Table I. Failure to conform to the requirements

4.16 Acceleration. Test and record the acceleration of the truck from a standing start over a measured distance of not less than 20 ft. Failure to conform to the requirements

4.17 Service Brake performance. Test the truck in accordance with ANSI/ITSDF B56.1.

Failure to meet the requirements of this safety standard shall constitute failure of this test.

4.17.1 Brake Production Test. For testing of production trucks, service brakes and regenerative braking shall only be demonstrated to be functional and operating normally.

4.18 Resistance to saline atmosphere. The truck shall be tested fully assembled and in accordance with MIL-STD-810, Test Method 509.6, Salt Fog. Upon completion of testing a final test report shall be prepared and submitted per CDRL A014 (SALT FOG TEST

REPORT). This report will be reviewed by NAVSUP, MHE Program Office engineering team. Generally, the results of this test can be subjective. It should be expected that discussions on the test’s final results, conclusions, and deficiency mitigation will be necessary and may result in revisions to the final report or some level of re-testing before NAVSUP WSS can provide concurrence and acceptance.

4.18.1 Assembled truck. Preparation of the assembled truck prior to exposure shall ensure that the exterior surfaces of the truck, including the exposed surface of each piston rod and excluding only surfaces such as those of lift chains which are lubricated in service use, are cleaned and exposed during this test. The rod(s) of the tilt and of the sideshift cylinder(s) shall be at full extension. The lift cylinder rod which is exposed when the lift assembly is lowered in accordance with 4.19.2.2 below shall be cleaned and exposed.

Components such as bearings, which are lubricated during in service use, shall be lubricated in accordance with the manufactures recommended maintenance practices prior to testing.

4.18.2 Details. Pursuant to paragraph 3.1 of Method 509.6, the following test information is given:

4.18.2.1 Exposure. Duration shall be alternating 24-hour periods of salt fog exposure and drying conditions for a minimum of four 24-hour periods (two wet and two dry). During testing the truck shall not be washed or operated until all exposure and drying periods have been completed.

4.18.2.2 Configuration. Assembled truck resting on load tires with drive wheels elevated to place truck at required plane of traveling longitudinal stability, with mast at full forward tilt and carriage at maximum sideshift to expose rod of shift cylinder if provided, and with mast lowered to where tips of forks rest on 4" x 4" wood blocks.

4.18.2.3 Salt Solution. Salt concentration 5 percent.

4.18.3 Additional guidelines:

4.18.3.1 Inspection. Visual inspection after 24 hours and 72 hours exposure, but no washing or operation until after all exposure and drying periods are complete.

4.18.3.2 Evaluation. Evaluation will be based on the guidelines of MIL-STD-810, Test Method 509.6, paragraph 5.

4.19 Power consumption. Test the truck in accordance with Test Method No. 14. Failure to conform to the requirements paragraphs listed in Table I herein shall constitute failure of this test.

4.20 Heavyweight High-Impact (HI) shock test. The truck, with battery, shall be tested by the contractor in accordance with MIL-S-901. The contractor shall locate a non-government shock test facility, arrange the test, ensure proper tiedown assemblies are utilized, and take account of all related costs of this test.

4.20.1 H.I. Shock Test Plan. 60 days prior to testing, contractor shall submit a formal test plan for approval by the Navy HI-Shock technical warrant holder. Procedure shall indicate applicable documents, test requirements, description of test, hardware configuration, preparation for testing, visual inspections, initial operational tests, evaluation of damage, shock test report, definition of failure, cause for rejection, and completion of shock testing/post shock examination. CDRL A015 (HI SHOCK TEST PLAN) applies;

4.20.2 Ordering Data. Pursuant to 6.2 of MIL-S-901, the following ordering data shall apply to the first article truck and battery which shall be mounted on the Floating Shock Platform during test and to the trucks furnished by the supplier:

(a) "Shock tests: H.I. (High Impact) Shipboard Machinery, Equipment and Systems, Requirements For, MIL-DTL-901E dated 20 June 2017."

(b) Test category: Heavyweight.

(c) Grade A shock compliance required.

(d) The truck is class I, modified. The modification is that the truck rests on solid rubber or polyurethane tires which are similar in action to some resilient mountings.

(e) Type A test in which the truck is the principle unit and the battery is a subsidiary component.

(f) The truck is deck mounted.

(g) The truck is base mounted.

(h) The truck is unrestricted orientation.

(i) The truck with battery installed shall be secured to the deck simulator of the floating shock platform with tie downs furnished by the testing laboratory.

(j) N/A

(k) The truck shall not be in its normal stowed configuration and not operated during shock events. Following each shock event, the truck shall be operated to verify it is still fully functional and capable of performing at its rated capacity. This inspection and test shall include lifting, lowering, and sideshift of carriage forward and reverse drive, and operational steering.

(l) Following the final test event the truck and battery shall comply with (k) above and the battery shall successfully demonstrate that it can reach rated capacity. Not more than 2 cycles of charge shall be allowed after the HI-shock testing. Failure of the truck to comply with (k) or any deficiency preventing operation of truck, shall be regarded as failure of the truck to meet the HI Shock requirement.

(m) N/A

4.20.3 HI-Shock Final Test Report: Upon completion of testing a report shall be compiled following the outline of the approved test plan and compiling all the data and results from testing. This report shall include: detailed description of the ability of the unit under test the meet HI-Shock requirements, and identified discrepancies or induced failures identified during testing, post-test evaluation findings both at the test facility and during the teardown inspection by the manufacture’s (Grade A only) in accordance with the requirements of Mil-DTL-901. This report shall be provided to NAVSUP for review and concurrence not later than 30 days after completion of testing. CDRL A016 (HISHOCK

TEST REPORT) applies.

4.21 Rain Test. Test the truck in accordance with Mil-STD-810, test method 506.6, Procedure

I.

4.21.1 Pursuant to paragraph 3.1.b of test method 506.6, the following information applies:

4.21.1.1 Rainfall rate. Rainfall of not less than 4 inches per hour.

4.21.1.2 Exposure Surface (Orientation)and Duration. Expose all four sides of the truck individually to windblown rain for a period of 30 minutes per side. The simulated rainfall shall impinge on the truck at an angle of 45 degrees, ±5 degrees. The simulated rainfall shall disperse uniformly over the surface under test.

4.21.1.3 Preheat Temperature. At the beginning of the test the truck shall be at a temperature of at least 18 degrees F higher than the rain water temp.

4.21.1.4 Initial water temperature. See 4.22.1.3

4.21.1.5 Wind Velocity. Wind velocity shall be 40 mph.

4.21.1.6 Water Pressure. N/A

4.21.1.7 Droplet size. Droplets having a diameter range predominantly between 0.06 inch to 0.14 inch, with an appropriate raindrop concentration per cubic meter of approximately 17 drops/cu-ft to 3 drops/cu-ft, respectively.

4.21.2 Evaluation. Upon completion of rain exposure, allow truck to sit for 5 minutes. During this time check for evidence of water penetration in gauges or pooling of water on the trucks exterior and interior compartments. Then turn the truck on and exercise all load handling and mobility functions. Turn off truck and let sit for 30 min. Then draw a sample of the hydraulic fluid from the bottom of the reservoir and check for the presence of water.

Failure to conform to the requirements paragraphs listed in Table I herein shall constitute

4.22 Truck exterior dimensions. Truck shall be measured to determine if it meets the exterior dimensions for length, width and collapsed height as listed the salient characteristic in Table 1 of Statement of Work. Noncompliance shall be cause for rejection of the truck.

4.23 Reliability. The truck shall be tested in accordance with Test Method No. 8. Any failures experienced shall be reported within 24 hours with a final investigation report provided within 30 days. CDRL A017 (Failure Analysis and Corrective Action (FACA) Report) applies Failure for the purpose of this test is defined as any malfunction which cannot be remedied within 60 minutes by adjustment, repair, or replacement action by Navy organizational level maintenance personnel using the manufacturer identified tools and parts and which may cause:

4.23.1 Failure to commence operation, cessation of operation, or degradation of performance capabilities of the truck below designated levels.

4.23.2 Serious damage to the truck by continued operation.

4.23.3 Serious personnel safety hazard.

4.23.4 Simultaneous malfunctions traced to the same root cause are considered as one failure.

4.24 Electromagnetic interference characteristics. The truck shall be tested as specified in MIL-STD-461 and MIL-STD-464.

4.24.1 MIL-STD-461. The contractor shall locate a non-government EMI testing facility, arrange the test, and include all related costs of this test within their quote. Electromagnetic interference characteristics for radiated emissions, procedure RE101, shall be used with the limits shown in Figure RE101-2 over a frequency range of 30Hz to 100kHz. Procedure RE102 shall be used with limits shown in Figure RE102-1 over a frequency range of 10kHZ to 18GHZ. For susceptibility to electric fields, procedure RS101 shall be used with the limits shown in Figure RS101-1 over a frequency range of 30Hz to 100kHz. Procedure RS103 shall apply with a frequency range from 2MHz to 18GHZ at a limit level of 200 volts/meter.

4.24.2 General. RE101, RE102, RS101 & RS103 Operating Modes are specified as electronics on, engine on. For the emissions and susceptibility testing the engine shall be on to capture any of its emissions and verify that any of the vehicle controls are not susceptible to this susceptibility stimulus. For RE101, the test plan shall include a mitigation distance for any RE101 failures.

4.24.3 MIL-STD-464. Forklift shall be able to safely execute its mission while exposed to the flight deck electric field environment from Table 1 of MIL-STD-464. This test is performed and paid for by the Navy. The manufacturer will be invited to witness this test and will be responsible for any transportation design, development, parts and installation costs necessary to complete and pass this test. See Statement of Work for testing location and test engineer POC information.

4.24.4 EMI Test Plan. Prior to start of Mil-Std-461 testing, the contractor shall submit, for Navy approval, a formal test plan/procedure. This plan shall indicate applicable documents, test requirements, description of tests, hardware configuration, preparation testing, initial visual and operational tests, evaluation methods for test failures and related damage if applicable, final test report development and delivery deadlines, definition of failure, and reasons for rejection. CDRL A001 (ELECTROMAGNETIC INTERFERENCE (EMI) TEST

PROCEDURES) applies. This test plan will be forwarded by NAVSUP WSS to the Navy’s technical warrant authority for review and concurrence that testing may proceed. Testing shall not begin without acknowledgement from NAVSUP WSS that test plan has been accepted.

4.24.5 EMI Test Report. Upon completion of EMI testing a final test report shall be submitted for

NAVSUP and Navy Tech Warrant review and approval. CDRL A002

(ELECTROMAGNETIC INTERFERENCE (EMI) TEST REPORT) applies.

4.25 Diagnostics. Demonstrate the full capabilities of both onboard and/or external device diagnostics with specific emphasis on performance parameters that can be altered by maintenance personnel and if these settings will/can be disabled or protected from unauthorized adjustments. Diagnostic information must be easily understandable and displays shall be readable in direct sunlight. System updates shall not require either external devices to be connected to or executable files loaded on Navy computers.

4.25.1 Diagnostics Production testing. For production testing each truck shall have the diagnostic system checked to verify that no faults/deficiencies with the unit are currently registering and none are retained in memory. Contractor shall investigate and correct any faults being identified by the diagnostic system and remove any fault history that may be stored.

4.26 Temperature. First article test truck with battery shall be tested by the contractor in accordance with MIL-STD-810 for both high and low temperature operation as follows:

4.26.1 High Temperature. High temperature test shall be conducted following MIL-STD-810, test method 501.6 utilizing the requirement of Procedure II – Operation. Truck shall be operated only during the period of maximum response (highest item temperature).

Testing shall consist of three (3) cycles run under the climatic category A1 - Hot Dry as described in Table 501.6-III of this test method with a maximum ambient temp of 120 degree Fahrenheit. During operational testing the truck shall:

(a) Be in standard operating configuration with all lights turned for the full testing period.

(b) Demonstrate that the truck can move and steer in both forward and reverse direction while lifting maximum rated load.

(c) Demonstrate that maximum rated load can be lifted to the maximum height allowed within the test chamber.

(d) Demonstrate full capability to sideshift forks and full range of mast tilt both forward and aft with maximum rated load. (Raising load to max lift height is not required during this test).

4.26.2 Low temperature. Low temperature test shall be conducted following MIL-STD-810, test method 502.6 utilizing the requirement of Procedure II – Operation, at a temperature of 0 degrees Fahrenheit. Truck shall be exposed to this low temperature for a period of 4 hours following temperature stabilization. After the 4 hour period, the truck shall be operationally tested. The requirements for this operational test are:

(a) Be in standard operating configuration with all lights turned for the full testing period.

(b) Demonstrate that the truck can drive and steer in both forward and reverse direction while lifting maximum rated load.

(c) Demonstrate full capability to sideshift forks and full range of mast tilt both forward and aft with maximum rated load. (Raising load to max lift height is not required during this part of the test).

(d) Demonstrate that maximum rated load can be lifted to the maximum height allowed within the test chamber.

4.27 Battery and Connectors. Inspect battery and confirm:

4.27.1 Battery is VRLA type.

4.27.2 Battery voltage shall be checked prior to all tests requiring truck to operate and results documented with each test’s results.

4.27.3 Demonstrate that battery compartment offer easy access for servicing and removal of battery. Inspect that battery compartment does not restrict the operators line of sight.

4.27.4 Inspect battery connector and verify they comply with requirements of the Statement of Work.te

4.28 Hydraulic Cylinders and hoses.

4.28.1 Inspect cylinder manufacturer’s data to confirm that hydraulic cylinders are manufactured using materials as specified in the Statement of work.

4.28.2 With the rated load lifted, demonstrate that the decent of the carriage will stop automatically if there is a loss of pressure in the hydraulic system. Also demonstrate that the manual valve for lowering the load is in a safe and easily accessible location

4.28.3 Inspect the manufacturer’s specification on all hydraulic hoses and confirm thermoplastic hoses (SAE J517) are not used.

4.28.4 Inspect that brake and drive hydraulic systems (if applicable) are separated from the main hydraulic system.

4.28.5 Inspect hydraulic system component documentation to ensure the proof pressure of each component is at a minimum twice the working pressure.

4.29 Lubricants and hydraulic fluids. The contractor shall provide a listing of all lubricants and fluids which shall identify if each item conforms with acceptable fluids as reported in

MIL-HDBK-267.

4.30 Operator’s compartment and control panel. Inspect the operators compartment and control panel. Confirm all gauges, indicator lights and controls are clearly visible and easily reached. Inspect operator’s position is a side stance and proper cushioning is installed.

4.31 Master Switch. Demonstrate master switch functions without a key.

4.32 Hour meter. Inspect that an hour meter is installed and demonstrate that it is functioning.

4.33 Warning device. Demonstrate that the horn is operational.

4.34 Work Lights. Inspect that the required number of work lights are properly installed.

Demonstrate that they can be adjusted as required and inspect that they are installed and properly protected from damage.

4.35 Coatings and surface treatments. Inspect that the truck is correctly painted. Visually inspect that the surface coating is of a consistent color and gloss. Check coated surfaces for damage such as chips, scratches and corrosion or prep/application errors like runs, sags, peeling, or thin or missing coating. Inspect that areas, component and materials that should not be coated are free of paint (i.e. radiators, belts, cylinder rods, seals, etc.)

Inspect that non-slip coating is applied to the required areas/components as specified in

PD-1473.

4.36 Informational plates. Visually inspect that all required informational plates are attached and are readable.

4.37 Body and vehicle markings. Visually inspect all labels and marking. Confirm all required safety marking are included and markings are of the correct size and in the correct location.

4.38 UL-Safety rating. Inspect the truck to insure it is correctly placarded to comply with UL-safety EE safety rating requirements. Contractor shall provide for inspection a detailed listing of all components that have been added, modified or replaced to conform to EE UL requirements as well as information from the certifying laboratory (name, registration/index number, date of inspection, etc.).

5. Production quality conformance testing. Upon completion of manufacturing, all production trucks will undergo the Production Quality Conformance tests indicated with a “T” in column 2 of Table I. Any nonconformance must be traced to its root cause and production corrected to prevent reoccurrence. All trucks shall be defect-free when presented for Navy acceptance.

MAINTENANCE SERVICE AND INSPECTION SCHEDULE

FOR MATERIALS HANDLING EQUIPMENT - ELECTRIC

The following inspections and checks shall be made prior to power consumption test (Test Method No. 7) and the Production Quality Conformance testing. These tests shall also be accomplished before and after completion of the reliability test (Test Method No. 8). Contractor may also elect to perform these inspections prior to any FAT procedure. All deficiencies shall be corrected prior to initiating any test or accepting a production unit.

1. Using manufacturer’s lubrication chart, ensure forklift is properly lubricated.

2. Check all fluid levels; check for leaks; add fluid as necessary.

3. Check all instruments, controls, switches, lights, and horn for proper operation.

4. Check steering, brake system, travel disconnect, drivetrain (forward and rearward travel) for proper operation.

5. Proper operation of mast tilt and carriage lift/lower, sideshift and reach (if applicable).

OPERATIONAL NOTICE

When operation of the truck is included in any test method, the related truck systems being exercised shall be monitored to ensure normal operating parameters are not exceeded.

This monitoring includes but is not limited to: drivetrain temperature, hydraulic fluid temperature, fluid levels, system pressures, etc. Monitoring can be performed visually, using standard incorporated gauges or through the addition of instrumentation. Vendor shall identify the truck systems to be monitored and the monitoring methods within their FAT test procedures/plan.

TEST METHOD NO. 1

TIRE SIZE, TRUCK WEIGHT, TIRE LOADING, AND DECK LOADING

1. Test Apparatus:

(a) Platform scales or wheel scales

(b) Plywood panel

(c) Test Load – Rated capacity (4,500 lbs)

2. Test Procedure:

PART I – TIRE SIZE, TRUCK WEIGHT AND TIRE LOADING

(a) Inspect tire size and verify that it conforms to the dimensions identified in Tire and Rim Association (T&RA) Handbook.

(b) Determine the weight supported by each of the trucks wheels without a load on the forks. Position the truck’s drive and steer wheels onto individual axle scales.

With the carriage centered, forks off the ground, and the mast in a vertical position, document the scales readings. Confirm truck weight conforms to the requirement in Table 1.0 Salient Characteristics in Statement of Work.

(c) Determine the maximum weight supported by each of the wheels with maximum rated load on the forks. Position the truck’s drive and steer wheels onto axle scales. Initially the carriage shall be centered and the mast shall be vertical with the load and forks lifted off the ground. Shift the carriage and load to the extreme left and document the weight carried by each scale. Repeat this procedure with the load shifted to the extreme right. As necessary calculate the individual tire/wheel loads, record these values, and compare to the load limits in the T&RA Handbook.

PART II – DECK LOADING

(a) Cover the bottom of the drive and load wheels completely with slow drying paint and lower the wheels onto ¼ inch plywood panel to establish each tire contact area. Record each tire’s contact area.

(b) Calculate and record the actual deck loadings, with and without rated load, for each wheel by dividing the wheel weights determined in PART I – TIRE SIZE, TRUCK WEIGHT AND TIRE LOADING by the tire contact area determined in step

(a) of PART II – DECK LOADING.

TEST METHOD NO. 2

BATTERY PROTECTOR

(a) Potentiometer.

(b) Voltmeter/Mulitimeter

Note: Either Method A or Method B can be used to meet this testing requirement

Method A

(a) Verify with a potentiometer that battery voltage is 2.12 times the number of cells and that the signal light or fuel gauge indicates "full charge". Operate the lift control.

(b) Increase the value of potentiometer resistance observing voltage across the battery protector voltage terminal to 1.7 volts per cell and after one half hour observe that the warning light indicating "low state of discharge" has been activated. After a short interval of time (not to exceed 15 minutes) operate lift control and confirm lift will not operate.

(c) Unplug and then reconnect the battery and verify the lift control will not operate. Increase the voltage with the potentiometer to 2.06 volts per cell and observe that the lift control will operate and warning lights are reset.

Method B

(Note: Method B does not need to be incorporated in the FAT test plan as an isolated and separate test. It can be conducted in conjunction with any FAT test which sufficiently discharges the battery to the necessary levels to verify activation of battery protection circuits. If incorporated in another test method this shall be clearly identified in the test plan. When performed along with another test method, the battery protective test shall not be conducted if doing so may influence or invalidate the results of the primary test.)

(a) Operate truck until battery discharge indicator displays that approximately 30% of charge is remaining. Verify battery cell voltage by using a voltmeter/multimeter to measure the truck’s battery voltage and record this value. Divide the voltage reading by the number of cells in the battery and record this battery cell voltage number. This value should be approximately 1.98 volts.

(b) Operate the truck lightly until the battery discharge indicator and signal light indicate critically low state of charge.

(c) Operate the lift control to verify the function does not work and is locked out of operation.

(d) Unplug and then reconnect the battery and verify the lift control still does not function and is locked out of operation.

(e) Replace or recharge battery and verify discharge gauge and indicator light have reset and accurately reflect present battery discharge level. Verify the gauge reading by measuring and calculating cell voltage as described in paragraph (a) above. Correct fully charged cell voltage should be approximately 2.12 volts.

TEST METHOD NO. 3

SLOPE ASCENSION - PARKING BRAKE – TRAVEL DISCONECT - UNDERCLEARANCE

(1) Test Course:

(a) 15% grade ramp with a length of the sloped surface greater than the length of the truck under test. Sufficient level area shall be at both the base and top of the ramp to support the entire truck. Test course shall be dry, clean and free of any unplanned obstacles or foreign material.

(2) Test Apparatus:

(a) Clinometer.

(b) Go/No-Go gauge with height of 2.75 inch (Fabricated)

(c) Test load - Rated Capacity (4,500 lbs)

(3) Test Procedure:

(a) With the truck carrying the test load approximately 12” above the ground, park the truck on a smooth level surface. Sweep a 2.75 inch Go/No-Go gauge under the entire truck. Document any areas of interference preventing the gauge from passing under the truck.

(b) Remove the test load, raise forks enough to clear ramp and drive the truck in a forward direction along the horizontal approach and up a ramp of 15 percent grade.

Record any interference of truck with ramp. Bring the truck to complete stop once all wheels are full supported on the ramp.

(c) Apply parking brake and release service brake.

(d) Observe whether truck remains stationary for three minutes.

(e) Reapply the service brakes and release the parking brake.

(f) Drive the truck up the ramp and completely onto a horizontal surface. Record any interference of truck with ramp.

(g) Repeat steps 3(b) through 3(f) while carrying the test load sufficiently raised to prevent the test load from contacting the ramp.

(h) On a level surface, without a load, turn the on-off switch "on", depress deadman brake pedal and determine whether current to traction motors is cut-off and cannot be established until speed controller is moved first moved to the FWD or REV positions.

(i) Repeat step 3(h) for second operating platform position.

(j) Repeat steps 3(b) through 3(e) using only deadman brake.

TEST METHOD NO. 4

SHIPBOARD RAMP TRAVERSE

(a) Simulated Ship Door Sill Ramp: Construct ramp in accordance with Figure 1 from material of sufficient strength to withstand the loads applied during this test. A non-slip material may be applied to the surfaces.

(b) Test Load - Rated Capacity (4,500 lbs)

(a) With the test load raised sufficiently to prevent the test load from contacting the ramp, traverse the ramp in forward manner at low speed.

(b) Record any contact between the truck and the ramp.

(c) Repeat (a) and (b).

FIGURE 1.

SIMULATED SHIP DOOR SILL RAMP

Not to scale

TEST METHOD NO. 5

LIFT ASSEMBLY DRIFT

1. Test Course:

(a) Level, flat surface.

2. Test Apparatus:

(a) Temperature thermocouples.

(b) Clinometer.

(c) Test Load – Rated capacity (4,500 lbs)

3. Test Procedure:

(a) Install thermocouple in the hydraulic reservoir. Heat the hydraulic oil by exercising the lift, tilt and extension functions and maintain hydraulic oil temperature above 120 degrees Fahrenheit during this test.

(b) Raise test load to the maximum fork height. Set the mast to the true vertical position measured with the clinometer. Mark reference points to indicate the height of the mast.

(c) Record initial mast tilt and hydraulic oil temperatures.

(d) Hold for 10 minutes and measure and record any downward drift, rotational drift, and change in hydraulic oil temperature.

TEST METHOD NO.6

STRUCTURAL OVERLOAD

(a) Level, flat surface with appropriate anchor.

(a) Non-destruction inspection test equipment (magnetic particle (MT) or dye penetrant (PT) test method).

(b) Test Loads – 3 identical and stackable test weights of 4,500 lbs each; and one additional stackable test weight of 2,250 lbs.

(c) Crane or forklift

(d) Tie downs

NOTE: The following test steps (a) through (j) constitute the First Article Test procedure (300 percent of rated load).

Production Quality Conformance test procedure shall consist of the same procedure except that the total load applied to the forks shall be 150 percent of rated load (6,750 lbs) and that a visual inspection of the forks a minimum of 6 inches each side of the heel will be used in lieu of a non-destructive inspection test (MT or PT).

(a) Place truck on level surface and support it with blocks under the axle or frame to relieve strain on tires. Position mast in true vertical position, with forks in normal carrying position. External means may be utilized to hydraulically lock the tilt cylinder.

(b) Secure truck with tie downs to anchor in the test surface in a manner to compensate for the test loads to be placed on forks that are over the rated truck capacity.

Warning

When placing the load on truck, personnel shall stand clear. Crane operator shall be prepared to remove load in the event of immediate collapse or failure of the truck structure.

(c) With crane or another truck, place a test load of rated capacity in position such that the center of mass of the test load is on the truck's longitudinal centerline and at the rated load center.

(d) Check tie downs and hydraulic system for damage or leaks to determine whether the additional test load can be placed on forks. Tighten hold down devices as necessary.

Warning

When placing the load on truck, personnel shall stand clear. Crane operator shall be prepared to remove load in the event of immediate collapse or failure of the truck structure.

(e) With the crane or another truck, place the second test load carefully in position over the first load so that the center of mass of load is on the longitudinal centerline of the truck and at the rated load center. Once the first and second loads are applied and inspected in accordance with Step (d), proceed with positioning the third load on the first two loads so that the center of mass of load is on the longitudinal centerline of the truck and at the rated load center.

(f) If truck accepts the 300 percent test load without immediate failure, let overload stand on truck for 10 minutes.

(g) Remove load(s).

(h) Visually inspect truck structure, frame, mast assembly, and the hydraulic system for evidence of damage (deformation, fractures, leaks, broken welds, etc.)

(i) Perform a non-destructive test (MT or PT) on the forks. The area inspected shall be a minimum of 6 inches each side of heel.

TEST METHOD NO. 7

POWER CONSUMPTION TEST

NOTE: This test shall be conducted prior to reliability testing.

(a) Test course shall be dry, clean and free of any unplanned obstacles or foreign material. Refer to Figure 2.

(a) Test apparatus shall be identical to that of Test Method No. 8.

(a) Prior to testing, perform “MAINTENANCE SERVICE AND INSPECTION SCHEDULE FOR MATERIALS HANDLING EQUIPMENT - ELECTRIC”, as specified within this document.

(b) Test procedure shall be identical to that of Test Method No. 8, except that the duration of test shall be limited to 6 hours. The truck shall be run continuously for 6 hours over the test course with only one battery. Battery shall not be charged or changed during the test.

(c) Lap rate shall be 3 minutes 45 seconds +/- 30 seconds.

(d) Laps shall be timed and recorded.

(e) Record number of laps per hour.

(f) Observe that truck negotiated test course for 6 hours without changing or charging the battery.

NOTE: The number of laps performed during the Power Consumption Test shall be count towards the 2,000 laps for the reliability test (Test Method No. 8).

TEST METHOD NO. 8

RELIABILITY TEST

(a) Layout of course.

The test course shall be set up equivalent to the provisions of Figure 2. Aisle widths shall not exceed 14 feet. The course perimeter shall be demarcated with suitable barriers or indicators. Rubber pylons or other suitable marking shall be placed on all corners and other critical points to assist in keeping the truck being tested within the course limits.

(b) Obstacle inclusion.

The obstacle test shall be set up in accordance with the provisions of Figure 3, as a part of the test course. Iron, wood, cement or steel blocks may be used. A guideline 15 feet long shall be provided to the left of the centerline of the course and parallel to it. The inner edge of this guideline shall be at a distance from the course centerline equal to one-half of the truck width or one-half of the load width (whichever is greater) plus 6 inches. This spacing and arrangement will allow the left wheels of the truck under test to pass over the first block and then the right wheels to pass over the second block while the truck is moving forward in a straight line parallel to the guideline. It is required that all wheels pass over the obstacles.

(c) Ramp inclusion.

The course shall include a ramp constructed in accordance with the provisions of Figure 4.

(d) Course surface.

It shall be dry, clean and free of any unplanned obstacles or foreign material while conducting the reliability test. Refer to Figure 4.

(e) Pallet areas.

Pallet loads in the first pallet area shall be stacked in accordance with Figure

5. They shall be placed 2 inches apart in a direction parallel to, and touching in a direction perpendicular to the axis of the test course at that point. Side pallet stacks shall be high enough that the bottom of the top face of the top pallet in each stack is 6 inches below the maximum lift height of the vehicle under test. The stack marked "X" on Figure 2 shall be high enough that the bottom of the top face of the pallet, when placed upon it, shall be 6 inches below the maximum lift height of the vehicle. Pallet loads in the second pallet area shall be stacked in accordance with Figure 6. They shall be placed 2 inches) apart in a direction parallel to, and touching in a direction perpendicular to the axis of the test course at that point. Side pallet stacks shall be high enough so that the bottom of the top pallet will be approximately as high as the maximum lift height of the truck under test. The stack marked "Y" on Figure 2 shall be high enough that the bottom of the top face of the pallet, when placed upon it, shall be at the midpoint between ground level and the maximum lift height of the vehicle under test. Pallet loads in the third pallet area “Z” shall be stacked in accordance with Figure 7. They shall be placed 2 inches apart, positioned as shown on Figure 2, in a direction parallel to, and touching in a direction perpendicular to the axis of the test course at that point.

Side pallet stacks shall be one pallet load high (48 inches plus the height of the pallet).

Truck shall complete 2000 laps (Including laps completed in Test Method No. 7 – Power Consumption Test). Successful testing of Test Method No. 7 shall precede this test.

(a) The light switch shall be turned "off" and "on" and horn sounded at the beginning of each lap. The carriage shall be side shifted to both sides upon entering each pallet area.

(b) The truck shall begin each lap at the point labeled "START" on Figure 2. As the operator starts the truck, the horn shall be operated for approximately 1 second.

On lap number 1, the truck shall proceed in a forward direction, following the centerline along the portion of the course marked "A" until it reaches the first pallet area. The rated load will have been placed in this location on the stack marked "X".

(c) The truck shall make a 90-degree right-hand turn in one motion without backing, proceed to the face of the pallet stack marked "X", raise forks to maximum fork height so hydraulic relief valve is activated, adjust fork height, remove the loaded pallet. The truck shall back out of the stack aisle into the main aisle making a 90-degree left-hand turn in one motion, without going forward, and proceed rearward along the main aisle in the portion of the course marked "B" until it reaches the second pallet area.

(d) The truck shall proceed rearward to a point beyond the pallet area opening, reverse its direction, and move forward to the face of the pallet stack marked "Y", making the 90-degree right-hand turn in one motion without backing. The rated load shall be placed on top of the pallet stack marked "Y".

(e) The truck shall back out of the stack aisle into the main aisle, making the 90-degree left-hand turn in one motion without going forward, and proceed forward along the main aisle in the portion of the course marked "C" until it reaches the third pallet area.

(f) The truck shall make a 90-degree right-hand turn in one motion without backing and pick up rated load which has been placed in the location marked "Z". The truck shall back out into the main aisle, making the 90-degree right-hand turn in one motion, and proceed forward along the main aisle in the portion of the course marked "D" until it reaches the portion of the course marked "E", containing the obstacle blocks.

(g) The obstacle blocks shall be traversed by the truck in a straight line so that its left wheels pass over the first block and the right wheels pass over the second block.

This part of the test may be conducted at low speed; however, the truck shall not be stopped prior to or while going over the blocks.

(h) The truck shall proceed further along the main aisle in the portions of the course marked "F" and "G" until it reaches the position on the ramp labeled "Stopping Point". The driver shall stop the truck and then resume ascending the ramp. After the top of the ramp is reached, precede along the main aisle in the portion of the course marked "J", "K", and "L".

(i) When the truck reaches the portion of the course marked "M", the operator shall stop. On every other lap, the operator shall turn off the master switch, and then turn it "ON". After completion of this portion of the test, proceed along the main aisle and start the next cycle. All stops shall be at the maximum safe deceleration rate. The operator shall activate and release the parking brake at least once during each circuit.

(j) The truck shall then reenter the portion of the course marked "A". In portions "A", "B", "C", and "D", the procedure shall be the same as described in preceding paragraphs, except that the truck shall place a test load at each point where it was previously indicated…