J1_Statement_of_Work.pdf

Material Handling Equipment – Yellow Gear

CSUR Forklift Statement of Work

Name Title Signature

Gary D. Kimmel Contracting POC

Angela Benner Program POC

John Gehringer Engineering POC

1. SCOPE: This Statement of Work (SOW) covers the requirements for counterbalance style, stand-up rider, electric powered forklift trucks for use on Navy ships. The counterbalance, stand-up rider (CSUR) forklift trucks, shall be EE rated to comply with Navy requirements for the handling of weapons and ammunition. Being used aboard ship, the truck will be operated in a marine/salt air environment and this will include maneuvering in the tight confines of shipboard magazines, storerooms and cargo holds as well as occasionally performing outdoor/on-deck material handling operations and must meet the requirements within this SOW.

1.1 Background: The 4.5K CSUR forklift will replace the 4.5K reach and tier stand-up forklift currently in use on both aircraft carriers (CVN) and amphibious/dock landing (L-Class) ships.

2. APPLICABLE DOCUMENTS

2.1 Issues of Documents The following documents of the issue in effect on the date of the request for proposal, unless otherwise specified, form a part of this SOW to the extent specified herein. When documents conflict, this SOW shall govern.

AWS D1.1, D1.3, and D1.6 American Welding Society Structural Welding Code – Steel/Sheet

Steel/Stainless Steel

29 CFR, Part 1910 Occupational Safety and Health Standards (OSHA)

ANSI/ITSDF B56.1 Safety Standard for Low Lift and High Lift Trucks

MIL-STD-130 Department of Defense Standard Practice: Identification Marking of U.S. Military Property

MIL-STD-209 Interface Standard for Lifting and Tiedown Provisions

MIL-HDBK 267 Guide for Selection of Lubricants and Hydraulic Fluids for use in

Shipboard Equipment

MIL-STD-461 Requirements for the Control of Electromagnetic Interference

Characteristics of Subsystems and Equipment

MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems

NFPA 505 Fire Safety Standard for Powered Industrial Trucks Including Type

Designations, Areas of Use, Conversions, Maintenance, and

Operations

SAE J517 Hydraulic Hose

NAVSUP Publication 538 Management of Materials Handling Equipment (MHE) and

Shipboard Mobile Support Equipment (SMSE)

UL 583 Standard Safety for Electric-Battery-Powered Industrial Trucks

SAE AMS-STD-595 Colors Used in Government Procurement

MIL-STD-810 Environmental Engineering Considerations and Laboratory Tests

MIL-S-901 Shock Tests, HI (High Impact) Shipboard Machinery, Equipment, and Systems, Requirements For

NAVSUP WSS TE-1379 Testing Requirements Shipboard, Electric, Reaching and Tiering

Forklift Trucks

MIL-STD-3034 Department of Defense Standard Practice: Reliability-Centered

Maintenance (RCM) Process

DOD 4100.39 Federal Logistics Information System (FLIS) Procedures Manual

DOD 5010.12 Acquisition Management Systems and Data Requirements Control List (AMSDL)

ISO 9001 Quality Management

NAVICP PD-21861 Purchase Description, Manual, Technical, Material Handling

Equipment

MIL-P-23312 Pallets, Material Handling, Metal (For Ordnance Items) Mk 3 Mod

0, Mk 12, Mod 0 and Mod 1

MIL-P-24534 Planned Maintenance System: Development of Maintenance

Requirement Cards, Maintenance Index Pages and Associated

Documentation

MIL-STD-31000 Technical Data Package (TDP)

3. REQUIREMENTS

3.1 Classification. The truck shall be:

4,500-pound capacity at 24” load center with 68 inch overall (collapsed) height

3.2 Salient Characteristics. The forklift truck must meet the salient characteristics listed in

Table 1, as well as the additional requirements stated within this SOW.

Table 1.0 Salient Characteristics

CHARACTERISTIC TYPE 4

CAPACITY @ 24 INCH LOAD CENTER & TO FULL LIFT HT. 4,500 LB

MAXIMUM OVERALL LENGTH 115 IN.

MAXIMUM OVERALL COLLAPSED HEIGHT 68 IN. (see para 3.13.1)

MAXIMUM MAST HEIGHT EXTENDED 96 IN.

MINIMUM FREE LIFT HEIGHT. 20 IN.

MAXIMUM LIFT HEIGHT (TOP OF FORKS) 68 IN.

OUTSIDE TURNING RADIUS (MAX) 60 IN.

MAXIMUM OVERALL WIDTH 42 IN.

MAXIMUM TRUCK WEIGHT (NO LOAD WITH BATTERY) 10,000 LB

FORK DIMENSIONS (Length, Width, Thickness) 40 IN. x 3.5 IN. x 1.5 IN.

FORK SPACING, TOGETHER (MAX OUTSIDE DIM.) 15.75 IN.

(Rated Load/Unloaded)

MAXIMUM LIFTING SPEED (Not Less Than) 35 FPM / 45 FPM

MAXIMUM LOWERING SPEED (Not Less Than) 60 FPM / 65 FPM

3.3 Safety. The truck shall conform to the applicable requirements of ANSI/ITSDF B56.1, NFPA 505, UL 583, OSHA 29 CFR (Chapter XVII, Part 1910) and as specified herein.

3.3.1 UL Safety Rating. The truck shall be EE safety rated/certified to the requirements of UL 583. In addition, two (2) electrically conductive ground straps shall be incorporated to comply with Navy safety requirements of NAVSUP Publication 538. Labeling and marking of UL certification shall comply with the requirements as specified in this document.

3.4 Battery. The battery shall be rechargeable maintenance free Valve Regulated Lead

Acid (VRLA) either GEL or Absorbed Glass Mat (AGM). The battery shall be 36 or 48 volts.

3.5 Battery compartment. The battery compartment shall allow easy access to the battery for servicing and removal. The battery compartment shall not interfere with the operator’s line of sight to the fork tips.

3.6 Battery connectors. The battery connectors shall be EURO type-A32 female/male DIN

43589-1 with a mechanical latching system. Female/socket connector shall be installed on the battery cable and mounted to the forklift. The male/pin connector shall be installed on the truck’s cable and include a handle.

3.7 Hydraulic system. Hydraulics for the brake system and drive assembly shall be separate from the main hydraulic system. The main hydraulic system shall be designed to stop the decent of the carriage with the maximum raised rated load upon failure and loss of pressure.

A manual control for lowering of the raised load in the event of such a failure shall be included in a safe and easily accessible location. All system components shall be capable of a proof pressure that is equal to or greater than 2 times the maximum working pressure without external leakage, damage or permanent deformation.

3.7.1 Cylinders. All hydraulic cylinders shall be fabricated from either seamless steel tubing, or welded and redrawn tubing. To survive the rigors of the Navy shipboard environment, hydraulic cylinder rods shall have a finish offering state of the art corrosion resistance.

Traditional hard chrome plating for corrosion protection of steel cylinder rods has been proven to be insufficient so cylinder rod corrosion protective system used must exceed the performance of traditional hard chrome plating. The contractor shall provide scientific evidence to verify the corrosion resistant finish utilized for this contract meet this requirement. Cylinder rod finish must additionally pass the saline exposure testing described herein.

3.7.2 Hydraulic Hoses. Hydraulic hoses shall be properly restrained to protect them from unnecessary flexing, pressure surges or contact with other moving mechanical components. The use of thermoplastic hoses defined in SAE J517, such as 100R7, 100R8, and

100R18, are prohibited.

3.7.3 Hose and Tube Fittings: Hose and tube fitting used shall be fabricated of corrosion resistant steel or coated to withstand the highly corrosive conditions encountered when operating in a marine environment. Coatings shall not require routine reapplication to renew their effectiveness and shall comply with all environmental safety restrictions.

3.8 Lubricants and hydraulic fluids. The truck shall operate using only those lubricants and hydraulic fluids listed in MIL-HDBK-267.

3.9 Forks. The forks shall be attached to the fork carriage in accordance with ANSI

B56.11.4. Forks shall be end tapered on the underside to facilitate entry or withdrawal from double-faced standard military pallets conforming to MIL-P-23312. The top surfaces of the forks shall have a nonskid coating. With no load on the forks, the operator shall be able to see at least one fork tip at all lift heights and fork positions.

3.10 Carriage sideshift. The truck shall be equipped with an integral sideshift capability.

Side shifter shall provide for a minimum carriage movement of 3 inches on each side of center with rated load.

3.11 Service brakes. Service brakes are required at each drive wheel or motor. Brake lining shall not contain asbestos.

3.11.1 Regenerative braking. Truck shall incorporate regenerative braking to extend operating time.

3.12 Travel disconnect. Truck shall comply to all stand-up rider electric Truck travel disconnect requirements in ASME B56.1. The travel circuit shall disconnect automatically when the operator leaves the operating position. Similarly, the parking brake shall engage whenever the travel disconnect automatically actuates. The travel circuit shall be activated only by resetting the speed and/or directional control(s) when the operator assumes the operating position.

3.13 Parking brake. A parking brake shall be incorporated that is independent of the service brakes’ actuating system. Parking brake shall apply brakes to both drive wheels/motors.

Brake lining shall not contain asbestos.

3.14 Steer/drive tires. The tires shall conform to sizes and loadings as listed in the Tire and Rim Association (T&RA) Handbook for pressed-on or molded-on solid industrial tires. Static discharge/electrical type tire shall not be used and instead 2 static ground straps with polyurethane tires shall be incorporated.

3.15 Operator's compartment. Compartment shall have three enclosed sides with unobstructed entrance from the rear. Design of compartment shall allow truck operator to stand within the outline of truck and provide maximum visibility. Driver shall stand to one side and parallel to the longitudinal centerline of the truck (aka side stance) with a backrest/hip pad attached to the outer wall of the operator’s compartment.

3.15.1 Overhead Guard. To comply with the maximum overall collapsed height stated in

Table 1, an overhead guard shall not be installed on this truck.

3.15.2 Operator control panel. Controls, gauges and warning lights shall be ergonomically positioned so that all gauges, indicator lights and warning lights are clearly visible and all switches and controls are within easy reach during operation of the truck.

3.15.3 Master switch. A keyless master switch shall be provided.

3.15.4 Hour-meter. An electrically operated hour-meter shall be installed in the operator’s compartment and shall record the total number of operational hours for the drive/traction motor.

3.15.5 Warning device. The truck shall be equipped with an electric push button horn.

3.15.6 Battery protector. A battery discharge indicator, with lift cutout, shall be provided to protect the battery from approaching a dangerously low state of discharge. A dash mounted signal light shall visually alert the operator of a low charge condition.

3.16 Lifting and tie-down points. Permanently affixed lifting and tie down points shall be provided that enables the truck to be lifted in its stowed configuration and to be restrained to the ship’s deck of a transportation medium. Lifting and tie down points shall conform to

MIL-STD-209, for Type I equipment, excluding helicopter sling lift (HSL) and air transport requirements.

3.17 Work light. The truck shall be equipped with at least one work light mounted on the mast. This work light shall be an LED design rated at not less than 1,000 lumens. Directional adjustment range of this light shall be a minimum of 45 degrees above and below the horizontal plane. Horizontal adjustment range shall be a minimum of 300 degrees to illuminate front and rear areas. Adjustments shall not require the use of hand tools. Adequate protection against damage, by means of position or guard, shall be provided.

3.18 Structural load. The truck frame, forks, and related structures shall be capable of withstanding a load test (150% capacity) and an overload test (300% capacity) with no evidence of permanent deformation.

3.19 Travel speed. Truck shall be capable of attaining a travel speed of 5 miles per hour

(+/- 1 MPH) in forward and reverse directions, while traveling on a level surface with and without a rated load.

3.20 Slope ascension. Truck with and without rated load and traveling forward and in a straight line, shall be capable of ascending a 15 percent slope.

3.21 Fork tilt. When carrying rated load, the truck forks shall provide a minimum forward tilt of 2 degrees and a minimum rearward tilt of 4 degrees minimum. Tilt tolerance of +/- 0.5 degrees.

3.22 Under clearance. The truck with rated load shall have sufficient under clearance to permit safe operation traversing from one horizontal plane to another without scraping or dragging, using a slope of 15 percent. Under clearance beneath the mast assembly, when in a true vertical position with rated load shall be not less than 3 inches. Under clearance shall be not less than 3 inches under the entire truck.

3.23 Lift assembly drift. The lift assembly shall be capable of holding the rated load at maximum height and extension with not more than 1.75 inches of drift and not more than 1 degree of rotational drift for a minimum of 10 minutes with the hydraulic fluid temperature at 120

Fahrenheit.

3.24 Stability. The truck carrying rated load shall have longitudinal stacking stability on a 4 percent slope, longitudinal traveling stability on an 18 percent slope, lateral stacking stability on a 6 percent slope, lateral traveling stability on a 27 percent slope, rearward stacking stability on an 18 percent slope, rearward traveling stability on a 30 percent slope and static stability on a

46.5 percent slope.

3.25 Acceleration. From a standing start with rated load, the truck shall have an average acceleration rate in the forward direction such as to negotiate a distance of 22 feet in under 7 seconds.

3.26 Service brake performance. The truck shall have a service brake system that meets the performance requirements specified in ANSI/ITSDF B56.1.

3.27 Parking brake and travel disconnect system. The parking brake and the travel disconnect system shall each be capable of holding the truck with and without a rated load on a

15 percent slope in both the forward and reverse directions. Testing of brakes shall be accomplished only with the truck ascending the specified slopes in the forward direction.

3.28 Resistance to saline atmosphere. The truck shall withstand the corrosive effect of salt fog. The truck shall be prepared and tested in accordance with MIL-STD-810, Method

509.6, Salt Fog.

3.29 Power consumption. The truck shall be cycled continuously for 6 hours with one battery only and no recharging is allowed.

3.30 High-Impact (HI) shock requirement. The truck shall withstand Type A, Grade A, heavyweight HI shock in accordance with MIL-DTL-901.

3.30.1 Tiedown Assemblies for HI-Shock. The tie down assemblies used during HI-shock testing shall be Peck & Hale (CAGE 94658), Part Number 15MTC-1529 or equivalent as identified under NSN 2040-01-323-0772. Test facility shall determine the number of tiedowns required for testing and the forklift manufacturer is responsible to purchase these tiedowns and assure they are available for the scheduled test.

3.31 Electromagnetic interference (EMI) control. The truck shall undergo electromagnetic interference susceptibility and vulnerability testing in accordance with MIL-STD-

461 & 464. Acceptable evidence of meeting these requirements shall be a certified test report from an independent (MIL-STD-461) or Government (MIL-STD-464) testing laboratory that has been reviewed and approved by the Navy’s technical warrant holder. CDRL A001

[Electromagnetic Interface (EMI) Control Test Procedures] applies; CDRL A002

(ELECTROMAGNETIC INTERFERENCE (EMI) TEST REPORT applies. (See TE1374 - 4.24.4)

3.31.1 Government test facilities. The test for MIL-STD-464 shall be performed by

Naval Surface Warfare Center Dahlgren Division, E3 Assessment & Evaluation Branch (B52), 5493 Marple Road, Suite 156, Dahlgren, VA 22448. POC for testing procedure requirements and scheduling is Mr. Timothy Beatty, (540) 653-0808 timothy.beatty@navy.mil.

3.32 Rain. The truck shall be capable of starting within 5 minutes and be fully operational after experiencing rainfall conditions from testing per MIL-STD-810, test method 506.6 as described in TE-1374. Water shall not pool on the trucks exterior or inside of any compartments. All gauges/instruments shall be waterproof and water shall not enter the hydraulic system during this test.

3.33 Reliability. Truck shall complete 2000 laps around the endurance course specified in

TE-1374, Test Method 8.

3.34 Shipboard ramp traverse. Truck shall be able to traverse shipboard door sills and ramps as simulated in TE-1374, Test Method 4, without scraping or impeding forward motion.

3.35 Treatment and painting. All surfaces that are not corrosion resistant shall undergo proper surface treatment, pre-treatment and top coating to provide adequate corrosion protection for use within a marine/salt air environment. Surface prep at a minimum should include the removal of surface contaminants that are detrimental to paint adhesion. The use of plastic body filler compounds to cosmetically improve the exterior surface of the truck is not allowed. Pre-finished surfaces containing minor imperfections in their smoothness are acceptable and do not need to obtain an automotive quality flat/even finish provided that any imperfections will not compromise the integrity and durability of the corrosion protective coating system applied over the area. Steel and aluminum parts, when sufficiently durable, shall be pretreated by abrasive blasting. All abrasive blasting residues shall be removed from surfaces prior to applying primer and top coat. Corrosion protective coatings shall be lead and chromate free and approved for salt air environments. Primer coatings shall be a corrosion inhibiting epoxy type. Top or finish coat shall be compatible with the base/primer coating. The topcoat shall be resistant to impact and abrasion polyurethane or powder coated type. Both primer and top coat shall be applied to a uniform dry film thickness of 3 mils minimum. The finish color shall be 13538 in accordance with SAE AMS-STD-595. The top coat, when cured, shall be a uniform, even surface, free from runs, sags, peels, chips, blisters, and areas of thin film or no film. Lift chains, radiator, drive belts, instruments, cylinder seals, sprockets, rollers, plastics, fabric hoses

(except hydraulic hoses) and drive belts shall not be painted. Paint must be kept off working surfaces where interference with working parts would result in decreased or strained performance of the truck. Axles, transmission, engine and related accessories that are adequately coated by their manufacturers do not need to be repainted to comply with the required MHE color noted above and shall be adequately protected or masked from overspray.

Paint application shall meet applicable standard listed for either urethane or powder coated type mailto:timothy.beatty@navy.mil application (ASTM D7803, ASTM A153, or urethane paint manufacturer's recommended procedures).

3.35.1 Non-Slip coating. All steps, platforms and foot pedal pads shall be painted with a non-slip compound. Adhesive backed non-slip tape or panels are not acceptable.

3.35.2 Cadmium plating. The use of cadmium plating is prohibited.

3.36 Information plates. The truck shall be equipped with the following information plates conforming to MIL-STD-130. Plates shall be furnished and installed by the contractor.

3.36.1 Identification plate. The truck shall be equipped with an identification plate in accordance with ANSI/ITSDF B56.1. Additionally, this plate shall include the truck nomenclature: "TRUCK, FORK, STAND UP RIDER, ELECTRIC, MARINIZED", contract number, lifting capacity, lift height, USN registration number, shipping weight, cube dimension, technical manual stock number, warranty expiration date and manufacturer's name and address.

3.36.2 Shipping data plate. The truck shall be equipped with a shipping data plate that shows the silhouette of the truck in transport position indicating the center of gravity and the location and capacity of the lifting and tie down points.

3.36.3 Instruction, warning and caution plates. The truck shall be equipped with instruction plates including warnings, cautions and diagrams describing any special or important procedures to be followed in assembling, operating or servicing the truck. Commercially proven decals may be substituted for these instruction plates.

3.36.4 Wheel loading plate. The truck shall be equipped with a wheel loading plate to show wheel loadings on each wheel on truck with and without rated load.

3.36.5 Safety designation plate. The truck shall be equipped with a safety designation plate to show the manufacturer's name, complete model number, safety designation (Type EE), independent testing laboratory's name, independent testing laboratory's registration or index number assigned to the inspected truck, and the date and location of the independent laboratory's inspection.

3.36.6 Battery plate. The truck shall be equipped with a battery plate to show the battery weight, dimensions, ampere-hour capacity at a 6-hour rate, voltage, number of cells, number of plates, cable lead length and position.

3.37 Body marking. The truck shall have the USN number indelibly stamped into any fixed, non-removable plate within the operator’s compartment in a clearly visible location. Marking shall be in 0.25 in high block characters.

3.38 Vehicle marking. The truck shall be marked in black block letters, painted or vinyl, unless otherwise indicated, as follows.

3.38.1 USN registration number. The assigned USN registration number shall be marked in block numbers 3 inches high on each side of the truck.

3.38.2 Vehicle weight. The truck shall be marked with the letters “VW” followed by the truck’s empty weight (including battery) on each side of the truck in characters 2 inches high and in 1 inch characters on the back of the mast in plain view of the operator.

3.38.3 Safe working load. The truck shall be marked with the letters "SWL" followed by the truck's rated lifting capacity on each side of the mast in 2 inches high characters and 1 inch characters on the back of the mast in plain view of the operator. White numbers and letters may be used when the mast is painted black.

3.38.4 Safety designation. The safety designation (EE) shall be located on each side and the rear of the truck in accordance with UL 583 and NFPA 505.

3.38.5 Lifting and tie-down. Lifting points shall be marked with the terms “LIFT” or

“LIFT HERE” dependent on space available. Tiedown points shall be marked with the term

“TIEDOWN”. Both markings shall be in 0.75 inch high letters.

3.38.6 Rider Restriction. The truck shall be marked with "NO RIDERS" in 2-inch high letters on the rear of the mast.

3.38.7 Paint. The words "Painted with lead free and chromate free paint on (MM/YY) by

(Contractor Name)" shall be marked in 0.25 inch high characters on each side of the truck.

3.38.8 Brake linings. The words "NON-ASBESTOS BRAKE LININGS" and

"REPLACEMENT BRAKE LININGS TO BE NON-ASBESTOS“ shall be marked in 1 inch high letters on one side of the truck.

3.38.9 Shipboard use. The truck shall be marked with the words "SHIPBOARD USE

APPROVED" in 0.75 inch high letters on each side and rear of the truck. Batteries shall be marked with the words "SHIPBOARD CERTIFIED" in a conspicuous place on the battery case in 1 inch high letters.

3.39 Structural testing. The truck shall be marked with “STRUCTURALLY TESTED

‘DATE’ BY ‘MANUFACTURER OR FACILITY’, “in 1 inch high letters on each side.

3.40 Special tools and equipment. The manufacturer shall identify all special tools and equipment required for the Navy to diagnose and maintain the truck. Technical manual shall include specific details on how and when each special tool shall be used. (See para 5.1). All special tools and equipment shall be readily available to the Navy using the provisioning data provided by the contractor. (See para 5.1.1). CDRL A003 [Special Equipment Tools and Test Equipment List] applies.

3.40.1 Diagnostics. Start-up and Run diagnostics shall be provided. A built-in display and analyzer or plug-in handheld device shall be included which will allow the Navy full access to all status, fault and maintenance codes. Prior to first article testing, all programmable performance parameter will be set to comply with the requirements of this Statement of Work.

All adjustable parameters shall not be changed for the duration of FAT and all settings shall be recorded and documented in the first article test report.

3.40.1.1 For trucks reliant on hand-held diagnostic devices, the quantity and delivery address for the readers shall be specified in the contract.

3.40.1.2 In their proposal, the contractor shall provide a detailed description, specifications and instruction regarding all diagnostic components, tools, and equipment that will be provided either as integral within the truck or as hand-held tools.

3.40.1.3 Any Diagnostic system connector/port on the truck shall be physically secured to prevent access from unauthorized personnel.

3.40.1.4 Operating parameters shall be protected from unauthorized access, modification, and deletion. Prior to beginning FAT, the contractor shall brief personnel who will be the Navy’s witnesses during FAT events on the use of the diagnostic system. During FAT

Navy witnesses may randomly check setting against the values set prior to the start of FAT.

3.40.1.5 Prior to beginning each test within FAT, all fault codes and self-diagnostics shall be checked and any information recovered shall be documented and assessed for its impact on the scheduled test.

3.41 Temperature. Trucks shall be capable of starting and continuous operation under ambient temperatures ranging from 0 – 120 degrees Fahrenheit.

4. Regulatory Requirements

4.1 Recovered materials. The contractor is encouraged to use recovered materials to the maximum extent practicable in accordance with subpart 23.403 of the Federal Acquisition

Regulation (FAR). However, used, rebuilt or remanufactured components, pieces and parts shall not be incorporated in the truck.

5. Documentation

5.1 Technical Manuals. The technical manual should be created based on Purchase Description NAVSUP WSS PD-21861 dated 30 October 2018, Technical Manual, Material Handling Equipment.

5.1.1 Technical Manual Verification Review. The technical manual verification review will be conducted by the government (MHE ISEA) to validate that the truck's final technical manual accurately reflects the truck configuration, general information, operating instructions, safety rating, preventative maintenance, repair and overhaul, illustrated parts breakdown and parts list index. The truck will be operated only to the extent required to ensure that each section of the manual is accurate. Repair and overhaul operations will not be conducted, but will be reviewed for clarity. The illustrated parts breakdown and parts list index will be reviewed to the extent possible without major disassembly of the truck. The manual review shall be conducted after successful completion of first article inspection. The truck shall be available for review for a period of fourteen consecutive calendar days. Government review will be conducted at the manufacturer’s facility. A written list of discrepancies will be included in the pre-final technical manual review comments. CDRL A004 (Preliminary Technical

Manual Review) applies.

5.2 Provisioning.

5.2.1 Engineering Data for Provisioning (EDFP). Approved EDFP is required for all systems or equipment that are acquired for Navy use and for which Provisioning Technical

Documentation (PTD) is being acquired. EDFP is the technical data that provides definitive identification of dimensional, material, mechanical, electrical, or other characteristics adequate for provisioning of the support items of the end article(s) on contract. EDFP consists of but is not limited to data such as specifications, standards, drawings, photographs, sketches and descriptions, and the necessary assembly and general arrangement drawings, schematics, drawings, schematic diagrams, wiring and cable diagrams, etc., or what is sometimes referred to as form, fit and function. This data is necessary for the assignment of Source, Maintenance, and Recoverability (SMR) codes, for assignment of Item Management Codes, prevention of proliferation of identical items in the Government inventory, maintenance decisions, and item identification necessary in the assignment of a National Stock Number (NSN). EDFP format and content must be prepared in accordance with the latest industry standards and must be reproducible, as outlined below. Approved EDFP shall contain all appropriate annotations, i.e., proper Distribution Statements, Military Critical Technology markings, etc. Each item listed on the EDFP will identify the actual OEM in accordance with DOD 4100.39-M, Volume 1, paragraph 1.1.7 (f) (3). CDRL A005 (Engineering Data for Provisioning) applies.

5.2.2 Non-NSN Items. For items without an NSN, recognized industry standard or government specification or standard, the following order of precedence is required for EDFP provided by the contractor:

a) Technical Data equivalent to approved Product Engineering Drawings as defined in

MIL-STD-31000

b) Commercial drawings

c) Commercial manuals, catalogs or catalog descriptions

d) Sketches or photographs with a brief description of dimensional, material, mechanical, electrical or other characteristics.

5.2.2.1 Drawings: Drawings required to support provisioning shall be assembly drawings with complete bill of material identifying all parts. If subassemblies are listed on a drawing and not broken down, then drawings for the subassemblies are required as part of the drawing package. All assemblies and subassemblies shall have drawings that fully identify all parts that are encompassed within a component, sub-system, and system.

5.2.2.1.1 Supplemental Provisioning Technical Documentation (SPTD): If the actual OEM is not identified in the bill of material, SPTD in the form of catalog sheets, correspondence from the OEM (OEM letter head), email, etc. shall be submitted to identify the

OEM.

5.2.2.1.2 Proprietary Rights: A company's declaration of Proprietary Rights for their equipment does not negate the requirements of EDFP. All drawings are stored in a secure repository. A Proprietary Rights Statement shall be clearly included within the field of the drawing. Military critical or proprietary drawings are coded as such and access is restricted in a manner prohibiting contractors from being able to access, view, print, or obtain these proprietary drawings. Should contractor access be required it is limited to contractors working for DOD that have been vested and with current active Non-Disclosure letters on file.

5.2.3 Commercial and Government Entity (CAGE) Code. CAGE code reference numbers and units of measure/units of measure price (UI/UM PRICE) are required in order to generate national stock numbers (NSNs).

5.2.4 EDFP Applications. EDFP allows the Navy to develop:

a) Technical identification of items of maintenance support considerations

b) Preparation of item identification for the purpose of assigning NSNs

c) Review for item entry control

d) Standardization

e) Review for potential interchangeability and substitutability

f) Item management coding

g) Preparation of allowance/issue lists

h) Source, Maintenance, and Recoverability coding

5.3 MIP/MRC. Develop and deliver Maintenance Index Pages (MIPs) and Maintenance

Requirement Cards (MRCs) in accordance with MIL-STD-3034 and MIL-P-24534. Delivery for approval shall be in electronic format [New PMS Editor (NPE)] to the ISEA address listed below.

Developers for the MIPs/MRCs are to be (minimum) Level 2 certified. MIP/MRC must be acquired under separate contract line item in the contract. CDRL A006 (PLANNED

MAINTENANCE SYSTEM (PMS) MAINTENANCE INDEX PAGES (MIP)) applies; CDRL A007

(PMS MAINTENANCE REQUIREMENT CARD (MRC) applies.

ISEA:

Director

Naval Surface Warfare Center

Indian Head Division Detachment Picatinny

Building 458, Whittemore Ave.

Picatinny Arsenal, New Jersey 07806-5000

Attn: Bob Zalinsky

5.3.1 Recommended MIP/MRC developers. The following are

recommended developers which may be contacted for assistance in delivery of required MIPs/MRCs.

The McHenry Management Group (Chesapeake, VA)

Mike Reagan (757) 410-0233

DRS (Chesapeake VA)

Dan Nunn (757) 312-9300

EG&G (Norfolk VA)

Dale Hopper (757) 858-4784

AT&T (San Diego CA)

Stan Owens (619) 209-4605

ICI Services (Virginia Beach, VA), Tony Germanotta (757) 340-6970 (ext 128)

The above recommended developers may be contacted for assistance in delivery of required MIPs/MRCs.

5.4 Special Tools and Equipment. Special tools and equipment must be acquired under separate contracts. (See para 5.1)

5.5 Training. The contractor shall provide a one-time training course prior to the first production deliveries for Navy field technical experts with the objective that these students shall gain sufficient knowledge and experience to be able to then train Navy fleet forklift truck operators and maintenance personnel.

5.5.1 Class size shall be no more than 8 students.

5.5.2 The vendor shall provide a qualified training instructor, an appropriately sized and furnished classroom, an open area for forklift operation and any other related hardware or supplies required for this training.

5.5.3 Students will be furnished with copies of all teaching aids and documents necessary to conduct future classes to educate Navy operating and maintenance personnel.

Copies of all printed documents shall be provided in a CD/DVD format.

5.5.4 Training shall be conducted after successful completion of FAT but no later than

30 days prior to the first shipment of a production unit to the Navy.

5.5.5 Contractor shall determine the appropriate length of time for this class so that students receive a combination of classroom and hands-on training. Upon completing this course each student shall have:

A complete and detailed understanding of all systems of the truck and thorough knowledge of all potential hazards and the general safety information.

Detailed knowledge on all routine scheduled maintenance.

Sufficient hands-on experience to safely and proficiently operate the truck.

Detailed knowledge on the use of the diagnostic tool (refer to paragraph 3.37.1 -

Diagnostics).

5.5.6 A certificate of proficiency and completion of training shall be provided to each student upon successful completion of this class.

5.5.7 Not less than 14 days prior to the start date of training, a syllabus shall be provided. Syllabus shall include at a minimum the following:

Course location and start & finish date.

Course description and training strategy with breakdown of daily agenda.

Training elements and sequence of events

List of training materials and documents provided to students

List of personal protective equipment/clothing which students should bring

CDRL A008 (Syllabus – Factory Training) applies.

6. PROGRAM MANAGEMENT

6.1 The Contractor is responsible for maintaining their Systems Engineering and Program

Management policies and procedures to accomplish the tasks identified herein. The Contractor is responsible for planning, organizing, and managing the effort throughout the life of this contract. The Contractor is responsible for maintaining program costs, performance, and schedule to ensure requirements are being met, and to provide early detection of problems to resolve and reduce risk.

6.2 Conference Meetings. Contractor shall provide Agenda, Minutes, and Action Items List.

CDRL A009 (Conferences Meetings Agenda and Minutes) applies. The following meetings are required at a minimum:

6.2.1 Post-award Guidance Conference: This meeting will occur not later than 45 days after award. This meeting shall be held via teleconference. Contractor will present:

6.2.1.1 Overview of the specifications and performance of the forklift as listed in their proposal. Explaining how each paragraph in the Statement of Work will be met.

6.2.1.2 Present a schedule of key events from contract award to the delivery of technical manuals following the completion of first article testing (FAT). This schedule should include, but is not limited to: Pre-FAT testing performed by the contractor, estimated completion of build of FAT test unit(s), a basic schedule of FAT events, their order of occurrence and locations, and the planned delivery of all CDRLs during this time period.

6.2.1.3 Present any updates to the proposed forklift that may be realized since proposal acceptance/contract award.

6.2.1.4 Identify where in the program any risks are involved that may negatively impact the schedule.

6.2.2 Test Readiness Review: This meeting provides a detailed review of the contractor’s readiness to enter test with a high confidence that the equipment will successfully complete the testing. This meeting shall be scheduled not less than 30 days prior to the start of

FAT and will be held at the manufacturer’s facility. The contractor shall:

6.2.2.1 Present a detailed test schedule that is fully resourced and includes test dependencies.

6.2.2.2 Present any design or performance changes incorporated since the post-award briefing.

6.2.2.3 Provide a functional and operational demonstration of the forklift or display current progress of manufacturing of the FAT unit(s).

6.2.2.4 Identify any risks during FAT and how they can be mitigated to prevent or minimize the effect on the testing and production schedules.

6.2.2.5 Present the current state of development of the technical manual and

MIPS/MRC.

7. QUALITY ASSURANCE PROVISIONS

7.1 Contractor Certification

7.1.1 Equipment conformance. The contractor shall certify and maintain substantiating evidence that the product offered meets the characteristics of this Purchase Description and that the product conforms to the producer's own drawings, specifications, standards and quality assurance practices. Also, the item delivered is substantially the same product offered for sale in the commercial marketplace or is the same product that has been delivered to the government on a previous contract or purchase order. The government reserves the right to require proof of such conformance prior to first delivery and thereafter as may be otherwise provided for under the provisions of the contract.

7.1.2 Quality Assurance Program Plan. The contractor shall establish, implement, document and maintain a quality system that ensures conformance to contractual requirements.

The contractor shall implement the requirements of ANSI/ASQC Q9001, ISO 9001 or an equivalent quality system model: no third party certification is required. The contractor shall make their quality assurance program plan or quality manual (development of a Government unique document is not required) available for Government review at their facility as required.

The contractor shall officially notify the Government when they update their plan or manual throughout the contract period of performance.

7.1.3 Welds. Welded joints shall be sound, smooth, and free from harmful pits, holes, fissures, rough projecting edges, and slag; and shall be thoroughly fused to the base metal in accordance with AWS D1.1, AWS D1.3, and AWS D1.6.

7.1.4 Warranty. Unless otherwise specified in the contract or purchase order, the manufacturer's standard commercial warranty shall apply.

7.1.5 Interchangeability. Upon successful completion of testing and Navy concurrence all FAT requirements have been met, the production configuration of the truck is considered to be frozen. All hardware, material, components and assemblies incorporated in the truck shall be identical for every production truck under this contract. Should the contractor determine a configuration change is necessary during production, that change shall require prior government approval before production units can be altered. The contractor shall provide information and formally request the Navy’s approval by submitting an Engineering Change Proposals (ECP).

The ECP shall include all related changes to technical manuals (see paragraph 5.1), MIPs/MRCs (see paragraph 5.3) and provisioning data (see paragraph 5.2).

7.1.6 Engineering Change Proposals (ECP). ECPs are prepared and submitted to the

Contracting Officer in accordance with the configuration management requirements of associated Contract Data Requirements List (CDRL), DD Form 1423. CDRL A010

(ENGINEERING CHANGE PROPOSALS (ECP)) applies.

8. PREPARATION FOR DELIVERY

8.1 Packaging & Shipment

8.1.1 Packaging. Preservation, packaging, packing and marking for shipment shall be in accordance with the manufacturer’s standard commercial practice.

8.1.2 Freight on Board. Destination.

8.1.3 Transportation. The truck shall be shipped in enclosed type motor vehicles. If transportation terminals (way stations) are used, the truck shall be stored inside to prevent environmental damage.

8.1.4 Spray-on protective coatings. Sprayed-on coatings, applied to the fully assembled truck and used as additional and temporary protection during shipment, shall not be used.