Crash_and_Salvage_Cranes_Performance_Specification_-_Rev_A_with_Amendment_002.pdf

PRF-SPEC-PMA260C/7316

REV A 30 APRIL 2018

DEPARTMENT OF THE NAVY

PROGRAM EXECUTIVE OFFICE PMA260

NAVAL AIR SYSTEMS COMMAND

PATUXENT RIVER, MARYLAND 20670-1161

PERFORMANCE SPECIFICATION

FOR THE

CRASH AND SALVAGE CRANES

DISTRIBUTION STATEMENT A; Approved for public release; distribution is unlimited.

APPROVED: Signed 18 Dec 2017 APPROVED: Signed 19 Dec 2017

TITLE: Bob Steinbach

APEO(E) AIR 1.0/AIR4.1.1.4

TITLE: James Mathers

APEO(T&E) AIR-1.0/5.1.1

APPROVED: Signed 19 Dec 2017 APPROVED: Signed 19 Dec 2017

TITLE: John Jordan

APEO(L) AIR1.0/AIR 6.6

TITLE: CAPT Thomas Dall

PMA 260 Program Manager

Performance Specification for

CRASH AND SALVAGE CRANES

REVISION HISTORY

VERSION NO. DATE LOG OF CHANGES MADE AND DESCRIPTION OF

REASON CHANGED

BY

- 14 Dec 2017 Initial Release -

A 30 April 2018 Updated ship motion accelerations and CVN deck load limit curves

JC

Table of Contents

— ii —

1 Scope 1

1.1 Identification

1.2 System Overview

2 Applicable Documents 2

2.1 Government Documents

2.2 Non-Government Documents

3 System Requirements 7

3.1 Definition/ Concept of Operations

3.2 Characteristics

3.2.1 Performance Characteristics

3.2.1.1 Operator Control

3.2.1.2 Hoisting Capacities

3.2.1.3 Steering Control

3.2.1.4 Speed Control

3.2.1.5 Service Brakes

3.2.1.6 Parking Brake

3.2.1.7 Lighting Control

3.2.1.8 Monitor/ Display Status

3.2.2 External Interface Requirements

3.2.3 Transportability

3.2.4 Physical Characteristics

3.2.5 System Quality Factors

3.2.5.1 Fault Detection and Isolation

3.2.6 Environmental Conditions

3.2.6.1 Electromagnetic Radiation

3.2.7 Design Features

3.2.7.1 Nameplates and Product Marking

3.2.7.2 Power Plant

3.2.7.3 Hydraulic System

3.2.7.4 Electrical System

3.3 Design and Construction

3.3.1 Materials

3.3.2 Protective Treatments

3.3.3 Human Engineering

3.3.4 Safety

3.3.5 Workmanship

3.3.6 Interchangeability

3.3.7 Cybersecurity

4 Quality Assurance Provisions 36

4.1 Responsibilities and Test Parameters

— iii —

4.2 Engineering Development Model Testing

4.2.1 Visual Examination

4.2.1.1 Weight and Tire Contact Area Measurement

4.2.2 Functional Demonstrations

4.2.2.1 Emergency Towing Test

4.2.3 Idling Test

4.2.4 Boom Assembly Test

4.2.5 Hoisting Hook Speed Test

4.2.6 Lift Capacity Structure Test

4.2.7 Crane Stability Test

4.2.8 Load Indication Test

4.2.9 Lift and Move Capacity Test

4.2.10 Speed Capability Test

4.2.11 Loaded Service Braking Test

4.2.12 E-Stop Braking Test

4.2.13 Unloaded Service Brake Test

4.2.14 Parking Brake Test

4.2.15 Turning Radius Test

4.2.16 Top Plate/Top Access Panels Test

4.2.17 Lifting Attachment Test

4.2.18 Tiedown Attachment Test

4.2.19 Cab Heater Test

4.2.20 Cab Defroster Test

4.2.21 Cab Air Conditioner Test

4.2.22 Shipboard Shock Test

4.2.23 Storage in Wind

4.2.24 Low Temperature Operation Test

4.2.25 High Temperature Operation Test

4.2.26 Low Temperature Storage Test

4.2.27 High Temperature Storage Test

4.2.28 Relative Humidity Test

4.2.29 Salt Fog Test

4.2.30 Blowing Dust Test

4.2.31 Blowing Sand Test

4.2.32 Rain Test

4.2.33 Ice/ Freezing Rain Test

4.2.34 Fungus Test

4.2.35 Fault Detection/Isolation Test

4.2.36 Noise Level Test

4.2.37 Start Assist Receptacle Test

4.2.38 Maintenance Demonstration (MDEMO)

4.2.39 Reliability Demonstration (RDEMO)

4.2.40 EMI Compatiblity Test

— iv —

4.2.41 Electromagnetic Environment (EME) Test

4.3 Analysis

4.4 Production Acceptance Tests

5 Requirements Cross Reference 52

6 Notes 59

6.1 Acronyms

List of Figures

— v —

1 Crane Hook Section

2 CVN Deck load limits

3 LHD deck load limits

4 Deck allowable load reduction factor

5 Jack -Screw Extention…………………………………………………………………………...12

6 Identification Plate

7 RDEMO Course

List of Tables

— vi —

1 Minimum Boom Clearances

2 Coating Systems Selections

3 Verification Cross Reference Matrix

— 1 —

1 SCOPE

1.1 System Overview

The system described by this Performance Specification (PS) is for two Crash and Salvage Cranes; (1)

Aircraft Carriers (CVN), and (2) Amphibious Assault Ships (LHA/ LHD) to replace the legacy Carrier

Vessel Crash Crane (CVCC) and Amphibious Assault Crash Crane (AACC) presently in service. The cranes are required to handle damaged aircraft on the flight deck at sea so as to minimize impact on the recovery operations of other aircraft.

1.2 Document Overview

This PS establishes the performance requirements for the crash cranes, herein referred to as the Carrier

Crash and Salvage Crane (CCSC) or Amphibious Crash and Salvage Crane (ACSC). The requirements apply to both crane designs unless specifically identified as a unique requirement for the CCSC or the

ACSC.

— 2 —

2 APPLICABLE DOCUMENTS

Sections 2.1 and 2.2 list documents applicable to this specification to the extent specified here in. The current revision and most recent Notice of Change at the date of this specification shall be used unless otherwise stated.

2.1 Government Documents

SPECIFICATIONS

Military

MIL-DTL-15024 Plates, Tags, and Bands for

Identification of Equipment, General

Specification for

MIL-DTL-18264 Finishes, Organic, Weapons Systems, Application and Control of

MIL-DTL-53022 Primer, Epoxy Coating, Corrosion

Inhibiting Lead and Chromate Free

MIL-DTL-5541 Chemical Conversion Coatings on

Aluminum and Alloys

MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene

Types, JP-8

MIL-DTL-901 Shock Tests, H.I. (High-Impact)

Shipboard Machinery, Equipment, and

Systems, Requirements for

MIL-M-81807 Marking of Aircraft Ground Support

Equipment and Other Flight Line

Vehicles with Retro-Reflective

Materials; Process For

MIL-PRF-16173 Corrosion Preventive Compound, Solvent Cutback, Cold Application

MIL-PRF-23236 Coating Systems for Ship Structures

MIL-PRF-23377 Primer Coatings: Epoxy, High-Solids

MIL-PRF-32033 Lubricating Oil, General Purpose, Preservative (Water-Displacing, Low temperature)

MIL-PRF-32440 Coatings, Chip-Resistant

MIL-PRF-46010 Lubricant, Solid Film, Heat Cured, Corrosion Inhibiting, NATO Code - S-https://ewb.ihs.com/#/document/XCDTKFAAAAAAAAAA?qid=636455475469739325&sr=re-10-10&kbid=4%7C20027&docid=942833374 https://ewb.ihs.com/#/document/XCDTKFAAAAAAAAAA?qid=636455475469739325&sr=re-10-10&kbid=4%7C20027&docid=942833374

— 3 —

SPECIFICATIONS

Military

MIL-PRF-81309 Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film

MIL-PRF-81733 Sealing and Coating Compound, Corrosion Inhibitive

MIL-PRF-83483 Anti-seize Thread Compound, Molybdenum Disulfide Petrolatum

MIL-PRF-85285 Coating: Polyurethane, Aircraft and

Support Equipment

MIL-A-8625 Anodic Coatings for Aluminum and

Aluminum Alloys

MIL-L-23398 Lubricant, Solid Film, Air-Cured, Corrosion Inhibiting, NATO Code

Number S-749

MIL-S-8512 Support Equipment, Aeronautical, Special, General Specification, for the

Design of

STANDARDS

Military

MIL-STD-130 Identification Marking of US Military

Property

MIL-STD-1472 Human Engineering Design Criteria for Military Systems, Equipment and

Facilities

MIL-STD-1568 Materials and Processes for Corrosion

Prevention and Control in Aerospace

Weapons Systems

MIL-STD-209 Lifting and Tiedown Provisions

MIL-STD-461 Requirements for the Control of

Electromagnetic Interference

MIL-STD-464 Electromagnetic Environmental

Effects, Requirements for Systems

MIL-STD-810 Environmental Engineering

Considerations and Laboratory Tests

MIL-STD-882 DoD Standard Practice for System

Safety

MIL-STD-889 Dissimilar Metals

— 4 —

Federal

FED-STD-595 Colors Used in Federal Procurement

Other Government Agency

NAVFAC P-307 Management of Weight Handling

Equipment

DRAWINGS

1540AS100-1 Tiedown Assembly (TD-1B)

15MTC-1529 Tiedown Assembly with Elastomer

328AS289 Receptacle - External Power

3909AS9999 Plate, Identification

5SE00363-3 Plate, Modification

OTHER PUBLICATIONS

Regulation

DFAR 223 Environment, Conservation, Occupational Safety, and Drug-Free

Workplace

Handbook

MIL-HDBK-470 Designing and Developing

Maintainable Products and Systems

2.2 Non-Government Documents

ASTM D1655 Standard Specification for Aviation

Turbine Fuels

ASTM D975 Standard Specification for Diesel Fuel

Oils

AWS D1.1 Structural Welding Code - Steel

AWS D1.2 Structural Welding Code -Aluminum

AWS D1.6 Structural Welding Code –Stainless

Steel

— 5 —

AWS D14.3 Specification for Welding

Earthmoving, Construction, and

Agricultural Equipment

SAE AMS-S-8802 Sealing Compound, Fuel Resistant, Integral Fuel Tanks and Fuel Cell

Cavities

SAE AMS3265 Sealing Compound, Polysulfide (T)

Rubber, Fuel Resistant, Non-

Chromated Corrosion Inhibiting For

Intermittent Use to 360 °F (182 °C)

SAE AMS3276 Sealing Compound, Integral Fuel

Tanks and General Purpose, SAE AMS3277 Sealing Compound, Polythioether

Rubber Fast Curing for Integral Fuel

Tanks and General Purpose, SAE AMS3281 Sealing Compound, Polysulfide (T)

Synthetic Rubber for Integral Fuel

Tank and Fuel Cell Cavities Low

Density for Intermittent Use to 360 °F

(182 °C)

SAE ARP1247 Aircraft Ground Support Equipment

— General Requirements

SAE J198 Windshield Wiper Systems - Trucks, Buses, and Multipurpose Vehicles

SAE J381 Windshield Defrosting Systems Test

Procedure and Performance

Requirements—Trucks, Buses, and

Multipurpose Vehicles

ANSI/NCSL Z540 Calibration Laboratories and

Measuring and Test Equipment

ASME B30.5 Mobile and Locomotive Cranes Safety

Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks and

Slings

ASME B30.10 Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings

— 6 —

ASTM A380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless

Steel Parts, Equipment, and System

ASTM D4956 Retro-reflective Sheeting for Traffic

Control

ISO 10012-1 Quality Assurance Requirements for

Measuring Equipment

ISO 3411 Earth Moving Machinery - Human

Physical Dimensions of Operators and

Minimum Operator Space Envelope

NAS 411-1 Hazardous Materials Target List

NACE No. 2 Joint Surface Preparation Standard

Near-White Metal Blast Cleaning -

Item No. 21066; SSPC-SP 10

PCSA Standard No 4. Mobile Power Crane and Excavator and Hydraulic Crane Standards

RR-W-410 Wire Rope and Strand

SAE AIR1471 Torque Tightening Threaded Fasteners

SAE AS50881 Aerospace Vehicle Wiring

SAE J 514 Hydraulic Tube Fittings

SAE J1063 Cantilevered Boom Crane Structures -

Method of Test

SAE J377 Vehicular Traffic Sound Signaling

Devices (Horns)

SAE J765 Crane Load Stability Test Code

SAE J987 Lattice Boom Cranes - Method of Test

A-A-52550 Pintle Assembly, Towing, Manual

Release

— 7 —

3 SYSTEM REQUIREMENTS

3.1 Definition/ Concept of Operations

The cranes move crashed or damaged aircraft on the flight deck of US Navy Aircraft Carriers or

Amphibious Assault ships while operating at sea. The cranes will “Lift and Move” and “Lift” (and hold) as specified while subjected to the conditions encountered on the ship's flight deck at sea.

3.2 Characteristics

3.2.1 Performance Characteristics

a. The cranes shall meet all performance characteristics of this specification in the following sea conditions combined with maximum 25-knot winds (all vertical/ horizontal acceleration combinations must be met).

1) (CCSC only): 0.214g lateral, 0.078g longitudinal with 1.000 +/- 0.306 g vertical; 0.089g lateral, 0.095g longitudinal with 1.000 +/-0.458 g vertical

2) (ACSC only): 0.312g lateral, 0.092g longitudinal with 1.000 +/- 0.374 g vertical; 0.130g lateral, 0.111g longitudinal with 1.000 +/-0.538 g vertical

b. The cranes in their stowed configuration (perpendicular to ships longitudinal axis), shall withstand the following Storm Condition load factors while subjected to 30 psf wind force on the projected area:

1) (CCSC only): 0.727g lateral, 0.339g longitudinal and 1.536 g vertical

2) (ACSC only): 0.738g lateral, 0.243g longitudinal and 1.518 g vertical

NOTE: Wind forces and horizontal acceleration forces are to be applied simultaneously in the same direction. Vertical accelerations (minimum and maximum) are to be applied simultaneously with horizontal accelerations and wind forces. Assume a wind load of 1750 lbs for aircraft. Shape factor for projected area of the crane shall be rationally determined but in no case shall the aggregate shape factor be less than 1.4. Assume the aircraft vertical center of gravity is 110” from the deck and the aircraft is secured to the crane via straps.

3.2.1.1 Operator Control

The cranes shall be operated by a single person (operator) in the cab who must have an unobstructed view of the aircraft engagement area while operating the crane.

a. Remote Control (ACSC only) A tethered remote control station with a 50 ft cable shall be provided to permit control of the craning and vehicle forward and reverse travel (limited to

“creep” speed at one foot per second) functions

(1) The ACSC shall have a storage location for the remote control and cable.

b. Deadman Controls The craning function controls such as luff and hoist shall be return to center, dead man type.

(1) All remote control functions shall be return to center, dead man type.

3.2.1.2 Hoisting Capacities

The cranes shall meet the hoisting capacity requirements listed herein. The “Lift” capacity may include the use of a deployed inrigger, a deployed counterweight and/or extended rear axle. The Lift and Move

— 8 — capacity will be based on the inrigger retracted and the counterweight and extended rear axle deployed (if applicable). Both the “Lift” and the “Lift and Move” capacities shall be equal to or greater than the specified capacities at shorter outreaches. Clear outreach is measured from the front of the crane, not the load radius.

a. Lift Capacity The ACSC shall lift 39,315 lbs at a clear outreach of 24 ft, 46,800 lbs at 18 ft and 52,600 lbs at 13 ft while subjected to conditions in paragraph 3.2.1.

b. Lift and Move Capacity

(1) The CCSC shall have the capability to lift and move 63,000 lbs at 13 ft clear outreach, 52,400 lbs at 23 ft and 46,300 lbs at 25 ft when subjected to the conditions in paragraph 3.2.1. The counterweight/ extended axle may be deployed.

(2) The ACSC shall lift and move 39,315 lbs at 13 ft clear outreach

c. Crane Stability The crane stability, while lifting loads per the cranes respective load charts and subjected to the conditions in paragraph 3.2.1, shall conform to the requirements of ASME

B30.5 Section 5-1.1 except that the maximum load rating for Lift-only/ Lift-and-Move operations is to be based on 90% of the tipping load if lifting occurs with a deployed inrigger, or 80% of the tipping load if lifting occurs without a deployed inrigger. (Note: Stability calculations are to combine lateral and longitudinal accelerations by taking the square root of the sum of the squares).

3.2.1.3 Steering Control

The crane shall change directions under the control of the operator.

a. Steering Ratio Maximum turning limits shall be achieved with not more than 3.5 turns of the steering wheel stop to stop.

b. Turning Radius The turning radius shall be 35 ft maximum (30 ft as a goal), wall-to-wall when both extendable axle and counterweight (if applicable) are retracted.

3.2.1.4 Speed Control

The crane shall accelerate or decelerate upon command providing controlled movement both loaded and unloaded.

a. Speed Capability The crane shall perform the following requirements in the forward and reverse direction:

(1) The unloaded crane shall have a maximum travel speed of 5.0 (+/- 0.5) MPH.

(2) The crane with its maximum Lift and Move load (63,000 lbs at 13 ft for CCSC and 39,315 lbs at 13 ft for ACSC) shall have a maximum travel speed of 3.0 (+/-0.5) MPH.

(3) The CCSC, carrying 63,000 lbs at a 13 ft outreach and the ACSC with a 39,315 lb load at 13 ft outreach, shall maintain a speed of 1.5 (+/ - 0.5) MPH while climbing a 5 degree incline.

3.2.1.5 Service Brakes

The crane service brakes shall be operated by a foot pedal in the operator’s cab and meet the following stopping distance requirements:

a. Loaded Service Braking Requirement The service brakes shall stop the crane traveling with its maximum rated Lift and Move load at its maximum speed in a distance of 10 ft or less. The crane shall not vary more than one foot from a straight line while braking.

— 9 —

b. Unloaded Service Brakes The services brakes shall stop the crane when traveling at its maximum speed in a distance of 10 ft or less. The crane shall not vary more than one foot from a straight line while braking.

3.2.1.6 Parking Brake

The crane shall have a parking brake that simultaneously locks all drive wheels.

a. Parking Brake Operation The parking brake shall be applied by means of a single control located in the operator's cab.

b. Parking Brake Hold on a Slope The parking brake shall hold the unloaded crane (inrigger and counterweight not deployed) while subjected to a 12 degree slope for the CCSC, and a 17 degree slope for the ACSC.

3.2.1.7 Lighting Control

The crane shall have LED lighting to illuminate the hook, load, boom and cab area, as well as the surrounding crane perimeter as specified below:

a. Lighting operation Each light shall be controllable with an on/off switch by the operator in the cab.

b. Flood Lights White LED floodlights mounted on the boom and mounted on the crane chassis shall be provided that will illuminate an area of at least 25 ft x 25 ft in front of the crane where an aircraft will be located when it is to be lifted. The combined illumination of the floodlights shall be

28,000 candela minimum.

c. Cab Mounted Spotlights Cab mounted, adjustable spotlights (minimum of 75 degrees vertically and 360 degrees horizontally) shall be provided on the left and right sides of the cab roof, that can be aimed by the operator to illuminate areas in front of and to the rear of the crane. Each spotlight is to be white LED with 100,000 candela minimum.

3.2.1.8 Monitor/ Display Status

The crane shall monitor and display the following subsystem statuses to the operator.

a. Engine Operating Hours capable of showing a minimum of “XX,XXX.X” hrs

b. Fuel Level

(1) A yellow warning light shall be illuminated when the fuel level in the tank is 1/8th capacity and below.

c. Battery Voltage

d. Engine Temperature

(1) A flashing red warning light shall be activated when coolant temperature has reached the maximum.

e. Engine Oil Pressure

(1) A flashing red warning light shall be activated when the oil pressure has dropped to below the safe operating level.

f. Fault Warning Indicator

(1) Flashing warning light(s) shall be activated to identify non-critical (yellow light) and critical

(red light) faults

— 10 —

g. Warning Light Check The crane shall provide a single method for the operator in the cab to verify all warning lights are working.

h. Automatic Shutdown Systems with override

(1) activated by low engine oil pressure

(2) activated by high coolant temperature

(3) activated by low fuel, to prevent running dry.

(4) A bypass for each of these automatic shutdown systems shall be provided.

i. Parking Brake Indicator Light A red warning light indicating the parking brake is actuated.

j. Engine Speed shown in revolutions per minute (RPM).

3.2.1.8.1 Display Visibility Monitors, switches, warning lights and controls shall be clearly visible in all day and night conditions including bright sunlight.

a. Display brightness shall be operator controllable via a panel light dimmer.

3.2.2 External Interface Requirements

a. Aircraft Interface The crane shall interface with existing aircraft hoisting slings. In order to accommodate the terminal ring or link of the aircraft hoisting sling, the trapezoidal section of the major dimensions of the crane’s hoist hook shall not exceed 7 inches by 4.5 inches as shown in

Figure 1.

Figure 1 Crane Hook Section

b. Flight Deck Allowable Load Allowable deck loads specified in Figure 2 (CCSC), and Figure

3 (ACSC) are to be evaluated both in the operating condition with the worse case load lifted and subjected to the conditions of para 3.2.1.a, and in the stowed condition subjected to the storm conditions stated in para 3.2.1.b. The moderate seas limit shown in Figures 2 and 3 will apply for the operating condition. The storm seas limit shown in Figures 2 and 3 will apply for the stowed condition. Loads imposed on the deck by the crane (tires and inriggers) shall be within the loading limits established by the following:

- Contact Patch/Load conditions ‘below’ the moderate or storm sea curve (as applicable) (Figures

2 and 3) are acceptable.

— 11 —

- Smallest allowable contact patch area is 100 in^2, based on minimum patch dimensions of 10 in.

x 10 in. The load capacity curves are independent of patch orientation.

- Sum the areas of the directly adjacent closely spaced patches (clear spacing < 1/2 minimum patch dimension).

- Ship motion accelerations identified in paragraph 3.2.1 are to be applied simultaneously with the crane parallel, and also with crane perpendicular, to ship’s longitudinal axis.

Figure 2 CVN Deck load limits

0 2000 4000 6000 8000 10000 12000

CVN- Moderate

CVN Storm

A llo w ab le L o ad ki p s)

Contact Area (in^2)

CVN

Condition Range Equation

Moderate Sea

100 – 210 y = 0.0541x + 74.54

211 - 2110 y = 0.0177x +

82.212

2111 – 5415 y = 0.0083x +

102.04

5416 -

10000 y = 147

Storm Sea

100 – 1100 y = 0.018x + 75.182

1101 - 3550 y = 0.0102x + 83.82

3501 -y = 120

— 12 —

Figure 3 LHA/ LHD deck load limits

c. Deck Allowable Load Capacity Reduction

(1) The load limit curves (Figures 2 and 3) are intended to be used for single patch loads only.

However, they are used when there is a minimum of 10 ft of clear space (edge to edge) between two adjacent patch areas. When the clear spacing criterion is not met, and one (or both) patch area is greater than 40 square inches, the reduction factor (K), (See Figure 4), shall be applied to the loads associated with the patch areas.

Figure 4 Deck allowable load reduction factor

Y=0.05X + 0.5

L-Class Condition Range Equation

Moderate Sea

100 – 1000 y = 0.026x + 71.777

1001 -

10000 y = 0.0009x +

96.833

Storm Sea

10001 – y = 0.0157x +

62.015

2301 -y = 0.001x + 95.74

— 13 —

d. Jacks The crane shall incorporate jacking provisions/sockets to allow for tire changes aboard ship. The jacking provisions/sockets shall be compatible with the 35 ton axle jack presently used shipboard, PN 8704, Cage 02708. The interface component is the Screw Extension, shown in

Figure 5:

Figure 5 Jack - Screw Extension

3.2.3 Transportability

a. Transportation The crane shall withstand externally imparted vibration rigors of over the road truck transportation without incurring damage or degradation of performance as specified herein.

b. Emergency Towing Provisions The crane shall have provisions for towing if disabled,.

(1) The crane shall be equipped with pintle hitch assembles in accordance with Commercial Item

Description A-A-52550 Type II (40,000 pounds max GTW) front and rear.

(2) The pintle assemblies shall be mounted on the crane’s longitudinal centerline 24+/-2 inches above ground level.

(3) The disabled crane’s steer wheels shall be capable of being aligned in the towed direction.

3.2.4 Physical Characteristics

a. Dimensions

(1) The stowed configuration (boom lowered/ retracted, counterweight retracted/ stowed, rear axle retracted) shall have a maximum length of 34 ft, (not including the boom). The boom is permitted to extend up to 18 ft beyond this horizontal length limit.

(2) The operational configuration (counterweight extended/ deployed) shall have a maximum overall length (not including the boom) of 55 ft (CCSC) and 51 ft (ACSC). The crane shall be capable of transiting unloaded from its parking location to the incident area while at a length no greater than its stowed length (extendable counterweight and rear axle systems retracted).

(3) The overall width shall not exceed 16 ft.

(4) The overall height in the stowed/ parked configuration (boom lowered/ retracted, counterweight retracted/ stowed) shall not exceed 19.3 ft.

(5) The boom/hook in its stowed configuration must provide at least 9 ft clearance from the deck.

b. Ground Clearance The crane in its heaviest loaded configuration shall have a ground clearance of at least 7.5 inches.

c. Unit Weight The fully fueled crane shall weigh less than: 133,500 lbs (CCSC); 91,500 lbs

(ACSC).

— 14 —

3.2.5 System Quality Factors

a. Reliability Requirements

(1) For purposes of reliability evaluation, the crane's mission shall be treated as two phases:

Standby Operations and Lifting Operations. Standby Operations include: powered on and idling in place, available to conduct Lifting Operations. Lifting Operations include: transit to an aircraft, engagement with the aircraft, lifting the aircraft, carrying the aircraft to another location, lowering of the aircraft, disengagement from the aircraft, and transit to the original location. Each mission phase shall be independently evaluated.

(2) The Mean Time Between Failure (MTBF) for Standby Operations shall not be less than 594 hours in a Naval Unsheltered (NU) environment. This requirement includes both hardware and software. Failure consists of the crane not being capable of performing the Lifting Operation mission when called upon at a random point in time.

(3) The crane shall be able to conduct lifting operations without failure at 99.5% reliability with a confidence level of 90%.

b. Maintainability Requirements

(1) The crane shall have a Mean-Time-To-Repair (MTTR or c) of 3 hours or less, at the

Intermediate maintenance level.

(2) The total repair time for corrective maintenance (CM) actions shall consist of the sum of the times of each subtask element comprising the CM action, including:

i. Fault detection and isolation.

ii. Removal and replacement of the failed component.

iii. Calibration and/or alignment (if required).

iv. Replenishment with required working fluids/substances (if required).

v. Validation (checkout) of the repair

(3) Access doors shall be provided to facilitate access to components for servicing of (as appropriate) hydraulic fluid, fuel, engine coolant, and engine oil. Removable panels shall be provided to facilitate access to components for maintenance.

(4) No tools shall be required to perform pre-operational activities

(5) Large power train components such as engines, generators, hydraulic power packs shall be removable by the ships intermediate level maintainers on the flight deck using the 20K capacity fork lift truck (Liftking LK20SCB).

3.2.5.1 Fault Detection and Isolation

a. Fault Detection and Isolation Provisions Built-In-Test (BIT) shall automatically detect a minimum of 95% of faults which prevent the crane from performing its mission or those faults defined as “critical faults”. “Critical faults” are those faults which present a safety hazard rated

Catastrophic or Critical within the definitions of MIL-STD-882E. Faults to be excluded from automatic detection require Government approval.

Fault isolation shall include faults detected automatically by BIT and faults detected by other means. Using BIT, technical publications, test points and test features designed into the crane and other standard support equipment/tools, the fault isolation performance shall be:

— 15 —

95% of detected faults to 3 or fewer Shop Replaceable Assemblies (SRAs).

90% of detected faults to 2 or fewer SRAs

85% of detected faults to 1 SRA

The selection, quantity, and accessibility of test points and test features are to be compatible with the design of replaceable assemblies and items, and the level of maintenance at which the test points and features are used. An “SRA” is the lowest replaceable item consistent with the level-of-repair analyses results/decisions.

b. Fault Reporting/ Fault Indication Alarm indication shall be such that it is readily noticeable and facilitate accurate diagnoses. Faults shall be reported via a digital fault indicator.

Plain English fault descriptions shall be used. The fault indicator shall provide a fault summary screen which presents current alarms, a fault history screen which stores the most recent 1,000 faults in reverse chronological order (i.e., most recent fault first), and an engine fault screen capable of displaying SAE J1939 SPN Codes generated by the engine.

3.2.6 Environmental Conditions

The crane shall meet all requirements specified herein when subjected to the following environmental conditions.

a. Operating Temperatures The crane shall operate continuously in temperature conditions ranging from -20° F to 125° F.

b. Cold Starting of Diesel Engine The diesel engine shall start in cold weather (-20° F), without the use of ether.

c. Storage Temperatures The crane shall withstand storage temperature conditions ranging from -40° F to 140° F.

d. Relative Humidity The crane shall operate continuously in an environment with up to 95% relative humidity.

e. Salt Fog The crane shall operate continuously with exposure to a 5% sodium chloride solution at a fall out rate of 1.2 fluid ounces per hour per square foot of surface area and not sustain corrosion.

f. Rain The crane shall operate continuously in rain consisting of four inches per hour rain fall steady state, and with 40 mph winds.

g. Ice/ Freezing Rain The crane shall operate after being stowed in ice/freezing rain per Mil-

Std-810 Method 521.4. The crane shall also operate in an ice/ freezing rain environment.

h. Blowing Sand The crane shall operate after exposure to blowing sand (150 to 850 micron particle size) with wind speeds up to 40 mph and a concentration of .06 +/- 0.015 g/ft3.

i. Blowing Dust The crane shall operate after exposure to blowing dust particles (<149 microns) with wind speeds up to 20 mph and a concentration of up to 0.3 +/-0.2 g/ft3.

j. Storage in Wind The crane in its stowed configuration shall not experience any damage in wind up to 90 MPH.

k. Shipboard Shock The crane shall meet the shock requirements of MIL-DTL-901 for Grade

A, heavyweight equipment.

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3.2.6.1 Electromagnetic Radiation

a. Electromagnetic Interference (EMI) The crane shall meet the requirements of MIL-STD-

461 Table V, RE102 and RS103 for Navy surface ship topside equipment. If applicable for the design (e.g. power cables for heaters), CS114 and CS116 are also required.

b. Electromagnetic Environment (EME) The crane shall meet the EME requirements of MIL-

STD-464, Paragraph 5.3, Table 1.

3.2.7 Design Features

The crane shall comply with ASME B30.5 and PCSA 4 unless otherwise stated herein.

a. Design Characteristics The crane shall comply with Chapter 5-1 of ASME B30.5 except that the maximum load ratings based on stability requirements per paragraph 3.2.1.2.c and welding shall be per paragraph 3.3.5.f vice AWS D14.3.

b. Crane Structure The crane structure shall be designed such that the stresses induced during the required operations while subjected to the sea conditions detailed in paragraph 3.2.1 are accounted for and the strength margins of SAE J987 (rope support boom) or SAE J1063 (cantilever boom) are met.

c. Top Surface

(1) The top area of the unit shall be capable of supporting a 250 lb. person walking on it without damaging, bending or deforming it in any way.

(2) The horizontal top surfaces expected to be walked on shall be covered with black non-skid coating A-A-59166.

d. Door and Panel Security

(1) All hinged doors shall be provided with devices to secure them, and prevent them from damage, in the open and closed positions when subjected to wind gusts up to 90 mph (closed) or 40 mph

(open).

(2) Stops or bumpers shall be installed so that the doors (or stops), do not mark or scratch the paint.

(3) All door hinges shall be stainless steel and removable (not welded).

(4) Doors or panels shall be provided to facilitate access to components for maintenance and servicing of (as appropriate) hydraulic fluid, fuel, and engine coolant.

(5) All latches shall be keyless.

e. Boom Assembly

(1) The boom assembly may be either a fixed length pivoting boom or telescopic boom of two sections with powered extend / retract.

(2) If telescopic, the telescopic section shall be adequately supported on friction type wear pads to prevent metal- to-metal contact between the sliding sections.

(3) If boom luffing / hoisting is accomplished with hydraulic cylinder(s) the design shall be so that either the hydraulic cylinders are full retracted while the crane is in the stowed configuration or the hydraulic cylinder rods shall be designed (e.g. plated) so as to withstand continuous exposure to the shipboard flight deck environment.

(4) The crane boom, when operated, shall have the minimum clearances as specified in Table 1.

The distance indicated is from the bottom of the hook to the deck.

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Clear Outreach from the front of the Crane (ft)

Minimum Boom Clearance

Height (ft) – CCSC

Minimum Boom Clearance

Height (ft) - ACSC

2 17 17

4 20 17

13 24 24

18 26.5 24

25 26.5 24

Table 1 Minimum Boom Clearances

f. Wire Rope

(1) The crane shall be provided with a sufficient length of wire so the hook is capable of reaching

45 ft (CCSC) or 97 ft (ACSC) below deck level when the boom is fully extended and at maximum angle.

(2) A lower limit stop shall be implemented that ensures at least three (3) dead wraps remain on the drum.

(3) The wire ropes shall be in accordance with RR-W-410 and shall have safety factors not less than 5.

g. Safety Harness Provision The boom tip shall incorporate two pulleys properly sized for ropes supporting 250 pounds each.

h. Boom Angle, Length and Outreach (load radius) Indicators If the boom configuration is fixed (non telescopic), an indicator showing outreach (load radius) shall be provided. If the boom configuration is telescopic boom length and boom angle indicators shall be provided. These indicators shall be visible to the operator from the cab. The indicators shall match entries in the load chart and be useable to determine the allowable load limits.

i. Load Indicating and Warning Device A load indicating and warning device of the load-moment type shall be provided to perform the following functions for Lift-Only and Lift and Move operations (as applicable):

1) Provide reading of hook load in pounds; reading shall not be less than 100%, or more than 110% of actual load.

2) Provide boom length (outreach) in feet; length indicated shall be +/- 2% of actual length.

3) Provide percentage of rated capacity – (either bar graph or numeric).

4) Provide visual warning: amber light when 90 percent of rated capacity is reached; red light at

100 percent rated capacity.

5) Provide an audible alarm warning at a 100 percent rated capacity.

6) Function lockouts shall not be included.

j. Hoist Drum Rotation Indicator If the hoist drum is not visible from the operator’s cab, a drum rotation indicator shall be provided, in accordance with ASME B30.5 Section 5-1.3. The rotation indicator shall be located in the cab, to permit sensing by the operator.

k. Hoist

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(1) The crane shall be provided with a powered hoist drum.

(2) The hoist shall contain a self-locking / or self-energizing brake capable of holding the maximum rated load when subjected to the sea conditions specified in paragraph 3.2.1.

(3) An anti-two block feature shall be provided.

(4) The crane shall be equipped with a provision for emergency lowering of a load in the event of hydraulic or electrical failure this will require being able to hoist down.

(5) The parts of line of the hosting system shall be fixed / non changeable.

(6) The unloaded hoisting hook speed (lifting) shall be variable between 0 and 40 (+/- 4) feet per minute.

(7) The hoisting hook speed (lifting) with maximum load shall be variable between 0 and 20 (+/- 2) feet per minute.

(8) The lowering hook speed unloaded, and also with maximum load, shall be variable between 0 and 20 (+/- 2) feet per minute.

(9) The crane shall be capable of luffing and hoisting simultaneously.

l. Powered Load Lowering The load hoist drums shall be equipped with a powered reversing drive, and suitable control features to provide precision controlled power lowering of loads. The powered load lowering mechanism is to be capable of lowering the loads at a smooth, controlled rate of speed, without jerking, bouncing or slipping the load. A braking device may be used to assist the power lowering mechanism. The winch is not permitted to allow free fall.

m. Emergency Load Lowering The crane shall have the ability to lower a load without damage to the crane or its load in the event of an engine failure. This may require hoisting down and lowering the boom.

n. Hook

(1) The hook shall be a forged hook capable of handling the heaviest load listed in the load chart when taking into account the sea conditions specified in paragraph 3.2.1.

(2) The hook shall have a minimum design factor of 4/1.

(3) The hook shall be capable of meeting NDT requirements as specified in NAVFAC P-307, appendix E, section 1.4.4 and 1.4.5.

(4) The hook shall include a safety latch per ASME B30.10.

(5) An initial throat dimension base measurement shall be established by installing two tram points and measuring the distance between them. The tram points shall be installed by the hook OEM.

(6) The hook OEM shall provide certification the hook meets the NDT requirements. Initial tram point measurements shall be included on the certificate.

o. Hook Block The hook block shall incorporate an anti-friction type 360° swivel and pivoting hook.

p. Drive/Steering System Manual Disengage

(1) The drive system, brakes and steering shall be able to be manually disengaged/ released to facilitate being easily towed when the crane is disabled. The manual disengagement system shall be easily accessible without removal of access panels and not require the use of tools.

(2) It shall take no more than three minutes for two personnel to disengage the brakes, drive and steering system.

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q. Operator's Cab

(1) The crane shall be equipped with an enclosed cab and shall have a door with at least one window, which can be opened for ventilation.

(2) In addition to the door window, the cab shall be furnished with a front windshield, rear window, and side windows sized and located to provide the operator clear visibility for all operations.

(3) The windshield and all windows shall be safety glass.

(4) A front windshield shall have a wiper system meeting the wiped area viewing requirements of

SAE J198.

(5) The cab interior shall be furnished with water-resistant non- absorbent thermal insulation.

(6) The cab shall be located to maximize visibility of the boom and hook with the operator’s eyes at a height of approximately 16’ (from the deck) when seated in the cab.

(7) The cab shall include the following features:

(a) Heater

(b) Air Conditioner

(c) Defroster

(d) Control Panel(s) for travel and craning functions

(e) Steering Wheel

(f) Accelerator Pedal

(g) Brake Pedal

(h) Emergency Stop

(i) Indicator Panel with the appropriate gauges and indicators for the design of the crane (e.g.

engine RPM, lights and displays mentioned in paragraph 3.2.1.8)

(j) Light switches including panel light dimmer / on-off switch (mentioned in paragraph 3.2.1.8)

(k) (ACSC only) Remote control shut out switch

r. Cab Defroster

(1) The cab shall be provided with a defroster for the windshield, side and rear windows that meets the requirements of SAE J381.

(2) An operator variable blend of conditioned air from the air conditioner and heater shall be available through the defroster.

s. Cab Heater

(1) The cab heater shall be capable of raising the internal cab temperature from -20 F to at least 65

F within 60 minutes after heater is turned on (doors and windows closed).

(2) Air temperatures around any part of the operator’s/passenger’s body shall not vary by more than + 9 degrees F.

(3) Air velocity shall be adjustable either continuously or with not less than three settings (Off, Low, and High).

t. Cab Air Conditioner

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(1) The air conditioning system shall be capable of maintaining a temperature not greater than 85 degrees F under full solar load of 1120 W/m2 and at ambient temperature of 125 degrees F.

(2) This cab temperature shall be achieved within 10 minutes at the above conditions with engine operating at idle.

(3) Air conditioning controls shall allow the operator to regulate the air flow temperature, distribution and velocity.

(4) The air conditioning system shall be capable of achieving an internal cab air change every 15 seconds.

(5) The air conditioning system shall not degrade vehicle performance while operating under all mission profiles.

(6) Refrigerant used in the system shall be R-1234yf.

u. Emergency Stop

(1) Emergency stop buttons shall be located in the operator's cab, on each side of the crane easily accessible to anyone walking with the vehicle, and on the remote control (ACSC only).

(2) Activating the emergency stop button shall cause the loaded crane to stop in a straight line within 10 feet from top speed.

(3) It shall not take more than 30 seconds to restart the engine after an emergency stop button has been activated.

v. Lifting Attachments The crane shall be provided with lifting attachments per MIL-STD-209 to enable the crane to be lifted perpendicular to deck as the crane would be oriented during normal operations. The attachments shall be located such that, adequate clearance will exist between lifting slings and all exterior parts of the equipment when the crane is hoisted. The eye of each lifting attachment shall not be less than 3 inches inside diameter.

w. Tiedown Attachments The crane shall have swivel type tiedown rings, compatible with both

TD-1B (1540AS100-1) and 15MTC-1529 tiedowns. The tiedown provisions shall be of such design, location and number to enable the crane to be secured in such a manner as to prevent shifting or movement in any direction when subjected to the storm sea conditions defined in paragraph 3.2.1.b. The inside diameter of each tiedown provision shall be at least three inches and all edges shall have a minimum radius of 1/8-inch; use MIL-STD-209 for guidance.

x. Stabilizing Line Attachments The crane shall include attachment points to which load stabilizing lines are to be attached while performing aircraft Lift and Move operations lifts specified herein. The attachments shall comply with the requirements of MIL-STD-209 for cargo tiedown provisions.

y. Inrigger If required, the inrigger, when deployed, may extend beyond the front of the crane a maximum of 48” provided that it is low profile with a maximum height of 8” for the portion that extends beyond the front of the crane.

z. Drainage Structures shall be designed to prevent collection or entrapment of water and minimize moisture retention. All structural configurations are to be designed for water run-off, or have adequate sized and placed drain holes so as to prevent the water accumulation. As practical, ventilation considerations are to be made in the design to minimize moisture retention.

aa. Exclusion of Rain and Airborne Spray The crane, with doors and windows closed, shall be designed to prevent water intrusion into the system interior or sealed components.

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3.2.7.1 Nameplates and Product Marking

a. Nameplates and Product Markings All nameplates, information plates, etc. shall be affixed to the unit and appropriately located to facilitate operation, maintenance and safety. Configuration and layout shall be in accordance with A-A-50271. All plates shall be capable of withstanding the environmental requirements described in this specification.

b. Identification Plate The crane shall be identified in accordance with MIL-STD-130 to include a Unique Identifying Device (UID) label. The identification plate shall conform to

NAVAIR Drawing 3909AS9999; characters shall be photo etched, engraved or raised (indented characters shall be filled in with white enamel). The plate shall be securely attached to the unit in a readily accessible location and contain the following information:

(1) Nomenclature

(2) Manufacturers Part Number

(3) Manufacturers CAGE

(4) Type Equipment Code

(5) Serial Number

(6) Contract Number

(7) National Stock Number

(8) Type Designator

See below example. The square block is the location of the 1 inch square UID.

Figure 6 Identification Plate

c. Instruction Plates Instruction plates shall conform to MIL-DTL-15024, Type H, Style III.

These plates shall be suitably located in view of the operator (or maintainer as applicable) and contain clear, concise instruction for the operation of all controls.

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d. Transportation Instruction Plate Lift and tie down instruction plates conforming to MIL-

DTL-15024,Type H, Style III, shall be inscribed with:

1) a diagram showing the lifting attachments and lifting slings, the capacity of each attachment and the sling configuration including the length and size of the sling legs.

2) the type, quantities and location of tiedown eyes and tiedown lashings, and placement relative to deck sockets required to secure the crane.

e. Modification Plate A modification plate conforming to NAVAIR drawing 5SE00363-3 shall be provided in a clearly visible location. The plate shall be imprinted with the unit's serial number.

f. Reflective Marking

(1) The retro-reflective material shall be applied in accordance with MIL-M-81807 along the extreme perimeter of the equipment (including boom) to reflect its general outline configuration.

(2) Retro-reflective material shall be in accordance with ASTM D 4956, Type II, Class 1, color yellow with a minimum height of 1”.

g. Marking/ Stenciling Information, format, and lettering shall be in accordance with MIL-

STD-130 and sized to ensure visibility during normal operational use. Character size shall be between 1/2" and 2". Stenciling shall be done in gloss black color number 37038 of Fed-Std-595.

Adhesive labels comprised of 3M Scotchcal Film, Series 220 (or equivalent) using thermal transfer resin ribbon for lettering and graphics shall also be acceptable in lieu of stenciling. As a minimum the following shall be identified:

(1) Center of Gravity location

(2) Gross weight, including fuel with one inch or greater characters

(3) Tire pressure, if applicable (near each tire)

(4) Serial number

(5) “Lift Here" and “Tie Down” or "Lift/ Tie Down" as appropriate (near each lifting/tiedown provision)

(6) Fluid type and capacity (adjacent to each servicing cap or opening)

(7) Jacking locations

h. Warranty Sticker A warranty sticker shall be affixed to each unit in accordance with MIL-

STD-130. Each warranty sticker shall include the warranty start date and end date

i. Safety Marking Precautionary markings shall be provided as necessary to warn of hazardous conditions and precautions to be observed to insure the safety of personnel and equipment.

j. Load Capacity Charts Waterproof load capacity charts shall be provided in the operator's cab, listing rated load/ outreach capacities, operational sea motion (identified as 3 degree roll for

CCSC, 5 degree roll for ACSC) and wind limitations. The charts are to include the following capacities:

(1) Lift Only (as applicable) – inrigger deployed and not deployed if the design includes an inrigger

(2) Lift and Move – counterweight and rear axle retracted (as applicable)

(3) Lift and Move – counterweight deployed and rear axle extended (as applicable)

3.2.7.2 Power Plant

a. Diesel Engine

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(1) The crane shall utilize a Tier III diesel engine; A National Security Exemption allowing the use of a Tier III-compliant diesel engine has been obtained by NAVAIR. The diesel engine shall be commercially available and comply with EPA Tier III emission standards for non-road diesel engines. The contractor shall provide a Tier III engine certificate from the OEM.

(2) The internal combustion engine must have a crankcase ventilation system that will capture blow-by oil mist and not allow oil dripping.

(3) The engine crankcase shall have magnetic drain plugs installed.

b. Fuel Types The diesel engine shall be able to perform all requirements identified in this specification while the engine is utilizing any of the following fuels without the need for additional lubrication systems that would require reservoir servicing:

- JP-5 (MIL-DTL-5624) jet fuel

- JP-8 (MIL-DTL-83133) jet fuel

- F-24 (NATO) jet fuel

- Diesel fuel (ASTM D975)

- Jet A and Jet A-1 (ASTM D1655)

c. Fuel Filters

(1) Two fuel filters of the spin on type shall be provided in an easily accessible location.

(2) The primary filter or strainer shall have a filtration rating conforming to the engine manufacturer’s recommendation and be located between the fuel pump and tank.

(3) The secondary fuel filter shall be located between the fuel pump and injectors and have a filtration rating conforming to the engine manufacturer’s recommendations.

d. Fuel Filler

(1) Fuel filler caps shall be painted green, Color No.14090 of FED-STD-595.

(2) The filler cap shall be permanently attached to the equipment by a stainless steel chain.

(3) The fuel filler neck shall be in accordance with MIL-S-8512, have a minimum inside diameter of 3 inches to allow for use of the larger fuel delivery nozzles.

e. Fuel Tank (1) The fuel tank shall be constructed of stainless steel to resist corrosion.

(2) The fuel tank shall be equipped with a readily accessible shut off valve in the outlet fuel line connection.

(3) The fuel tank shall be equipped with an easily accessible magnetic drain plug at the lowest point in the tank.

(4) The fuel tank shall have internal baffles to prevent fuel sloshing and provide rigidity.

(5) The fuel pick up shall incorporate an easily removable 100 micron mesh strainer.

(6) An access plate of a minimum 7 inches in diameter shall be provided at the top of the tank to allow visual inspection and manual cleaning of the fuel tank interior.

(7) The fuel tank shall be located so that any overflow during filling will not impinge on the engine, exhaust system or electrical equipment.

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f. Fuel Tank Capacity The fuel tank shall be sized to accommodate a 12 hour shift without refueling. The calculation is to be based on 11 hours with the engine at idle speed and 60 minutes at maximum rpm.

g. Hand Priming Pump A hand priming pump shall be provided to assure delivery of fuel to the injector pump after performing maintenance on the fuel system or supply of fuel is depleted.

h. Exhaust System

(1) The exhaust system shall be constructed, protected and concealed so that inadvertent injury through burns to operating and maintenance personnel shall be virtually impossible.

(2) The exhaust muffler shall be of the commercially available spark arresting type.

(3) The exhaust gases shall be discharged vertically above the operator's head or at the rear or side rear of the crane within the crane outline.

(4) The exhaust system shall be routed clear of all fluid lines and fuel and electrical system components.