SAH_Spec_Initial_Release_Signed_8_Nov_2016.pdf

DESTRUCTION NOTICE

FOR UNCLASSIFIED, LIMITED

DOCUMENTS, DESTROY BY ANY

METHOD THAT WILL PREVENT

DISCLOSURE OF CONTENTS OR

RECONSTRUCTION OF THIS DOCUMENT.

PRF-SPEC-PMA260C/6247

12 OCTOBER 2016

DEPARTMENT OF THE NAVY

PROGRAM EXECUTIVE OFFICE PMA260

NAVAL AIR SYSTEMS COMMAND

PATUXENT RIVER, MARYLAND 20670-1161

SYSTEM SPECIFICATION

FOR THE

SHIPBOARD AIRCRAFT HANDLER

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

APPROVED: Digitally Signed 11-07-16 APPROVED: Digitally Signed 11-07-16

TITLE: Jennifer Young

APEO (E) AIR 1.0

TITLE: Michael O'Mealy

APEO (L) AIR 1.0

APPROVED: Digitally Signed 11-03-16 APPROVED: Digitally Signed 11-08-16

TITLE: James R. Mathers

APEO (T&E) AIR 1.0

TITLE: CAPT Jacobs

PMA 260 Program Manager

REVISION HISTORY

VERSION NO. DATE LOG OF CHANGES MADE AND DESCRIPTION OF

REASON CHANGED

BY

- 12 October 2016 Initial Release J. Choflet

Table of Contents

— ii —

1 Scope 1

1.1 Identification

1.2 System Overview

1.3 Document Overview

2 Applicable Documents 2

2.1 Government Documents

2.2 Non-Government Documents

3 System Requirements 6

3.1 Definition

3.2 Characteristics

3.2.1 Performance Characteristics

3.2.1.1 Operator Control

3.2.1.2 Draw Bar Pull

3.2.1.3 Lifting Capability

3.2.1.4 Speed Control

3.2.1.5 Braking

3.2.1.6 Parking Brake

3.2.1.7 Steering Control

3.2.1.9 Lighting Control

3.2.1.10 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

3.2.6 Environmental Conditions

3.2.6.1 Electromagnetic Radiation

3.2.7 Design Features

3.2.7.1 Nameplates and Product Markings

3.2.7.2 Power Plant

3.2.7.3 Hydraulic System

3.3 Design and Construction

3.3.1 Materials

3.3.2 Human Engineering

3.3.3 Safety

3.3.4 Workmanship

3.3.5 Interchangeability

4 Quality Assurance Provisions 28

4.1 Responsibilities and Test Parameters

4.2 Pilot Production Tests and Examinations

— iii —

4.2.1 Visual Examination

4.2.2 Functional Demonstrations

4.2.3 Idling Test

4.2.4 Draw Bar Pull Test

4.2.4.1 Tow Bar Interface DBP Test

4.2.5 Lift Capacity Test

4.2.6 Lift/ Attachment Mechanism Dynamic Tests

4.2.7 Speed Capability Test

4.2.8 Towed Load Braking Test

4.2.9 E-Stop Braking Test

4.2.10 Unloaded Braking Test

4.2.11 Parking Brake Slope Test

4.2.12 Parking Brake Skid Test

4.2.13 Steering Alignment Test

4.2.14 Steering Maneuverability Test

4.2.15 Turning Radius Test

4.2.16 Approach and Departure Angle Test

4.2.17 Fuel Tank Capacity Test

4.2.18 Lifting/ Tie down Test

4.2.19 Rail Road Impact Test

4.2.20 Transportation Vibration Test

4.2.21 Shipboard Vibration Test

4.2.22 Shipboard Shock Test

4.2.23 Storage in Wind

4.2.24 Low Temperature Operation Test

4.2.24.1 Low Temperature Storage Test

4.2.25 High Temperature Operation Test

4.2.25.1 High Temperature Storage Test

4.2.26 Relative Humidity Test

4.2.27 Salt Fog Test

4.2.28 Blowing Dust Test

4.2.29 Blowing Sand Test

4.2.30 Blowing Rain Test

4.2.31 Noise Level Test

4.2.32 Fungus Resistance Test

4.2.33 Start Assist Receptacle Test

4.2.34 Explosive Atmosphere Ignition Resistance Test

4.2.35 Emergency Manual Disengage Test

4.2.36 Top Plate/Top Access Panels Test

4.2.37 Fault Detection/Isolation Test

4.2.38 Maintenance Demonstration (MDEMO)

4.2.39 Reliability Demonstration (RDEMO)

4.2.40 Towing Test

— iv —

4.2.41 External Air Transportability Test

4.2.42 Electromagnetic Interference Test

4.2.43 Electromagnetic Environment Test

4.2.44 HERO Tests/ Certification

4.3 Analysis

4.4 Production Acceptance Tests

5 Requirements Cross Reference 44

6 Notes 51

6.1 Acronyms

List of Figures

— v —

1 Hangar Deck load limits

2 Deck allowable load reduction factor

3 GSE Shop Ramp

4 Identification Plate

List of Tables

— vi —

1 Verification Cross Reference Matrix

— 1 —

1 SCOPE

1.1 Identification

This document establishes the system requirements for the Shipboard Aircraft Handler (SAH).

1.2 System Overview

The US Navy and Marine Corps currently have a requirement for a Shipboard Aircraft Handler (SAH) to replace the legacy A/S32A-32 aircraft towing vehicle (SD-2 Spotting Dolly) presently in service for shipboard hangar deck use. The SAH is to be a maneuverable, low profile, towbarless, diesel powered aircraft handling vehicle designed to tow, turn and spot Naval shipboard aircraft in the tight confines of the hangar bays aboard CVN, LHA and LHD class ships while at sea. The following aircraft are to be maneuvered aboard these ships: AV-8B, E-2C/D, F/A-18 (all variants), E/A-18G, F-35B/C, H-53E/K, H-60R/S, T-45 and V-22. The SAH will be designed to promote ease of operation with minimal specialized operator or maintenance personnel training.

1.3 Document Overview

This Performance Specification (PS) contains the requirements for the SAH.

Section 3 of this specification documents the characteristics required for the SAH. This section begins by identifying the performance characteristics due to functionality. It then identifies the objects with which this unit must interact. It then focuses on design constraints such as physical characteristics, environmental, system quality, and design and construction.

Section 4 specifies the methods to verify the Section 3 requirements have been met.

— 2 —

2 APPLICABLE DOCUMENTS

Sections 2.1 and 2.2 list external documents applicable to this specification. This specification takes precedence if a conflict exists between it and any other document specified herein. In those instances within this specification where commercial and military specifications are indicated as "guidance only," the contractor is given latitude in equipment selection, material selection, component selection, etc. This in no way relieves the Contractor from the responsibility of successfully passing the verifications called out in

Section 4 of this specification. Military specifications/standards and industry standards identified in this document establish minimum performance requirements. Equivalent or better specifications and standards may be substituted upon approval of the Navy. The current revision and most recent Notice of

Change at contract award 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-53022 Primer, Epoxy Coating, Corrosion

Inhibiting Lead and Chromate Free

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

MIL-DTL-81706 Chemical Conversion materials for

Coating Aluminum and Aluminum

Alloys

MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene

Types, JP-8

MIL-M-81807 Marking of Aircraft Ground Support

Equipment and Other Flight Line

Vehicles with Retro-Reflective

Materials; Process For

MIL-PRF-24667 Coating System, Non-Skid, For Roll, Spray, or Self-Adhering Application

MIL-PRF-85285 Coating: Polyurethane, Aircraft and

Support Equipment

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

Design of

MIL-W-5044 Walkway Compound, NonSlip, and

Walkway Mating

— 3 —

STANDARDS

Military

MIL-S-901 Requirements for Shipboard

Machinery, Equipment and Systems

H.I. (High-Impact) Shock Tests

MIL-STD-130 Identification Marking of US Military

Property

MIL-STD-1399 Electric Power, Alternating Current

MIL-STD-1472 Human Engineering Design Criteria for

Military Systems, Equipment and

Facilities

MIL-STD-1791 Designing for Internal Aerial Delivery in Fixed Wing Aircraft

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

Federal

A-A-59545 Jack, Dolly Type, Hydraulic, Automotive

FED-STD-595 Colors Used in Federal Procurement

TT-C-490 Chemical Conversion Coatings and

Pretreatments for Metallic Substrates

(Base for Organic Coatings)

DRAWINGS

1117AS242 Pin, Axle Aircraft Lifting

1117AS243 Pin, Axle Aircraft- Lifting

1479AS200-1 ALBAR Tow Bar

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

— 4 —

DRAWINGS

328AS289 Receptacle - External Power

3909AS9999 Plate, Identification

5SE00363-3 Plate, Modification

15MTC-1529 Tiedown Assembly

OTHER PUBLICATIONS

Regulation

40 CFR 261 Identification and Listing of Hazardous

Waste

40 CFR 302 Toxic Chemical Release Reporting:

Community Right-To-Know

40 CFR 355 Emergency Planning and Notification

40 CFR 372 Designation, Reportable Quantities, and Notification

40 CFR 51 Requirements for Preparation, Adoption, and Submittal of

Implementation Plans (Clean Air Act)

40 CFR 82 Protection of Stratospheric Ozone:

Leak Repair Requirements for

Appliances Using Substitute

Refrigerants; Final Rule (Clean Air

Act)

OTHER PUBLICATIONS

Handbook

MIL-HDBK-470 Designing and Developing

Maintainable Products and Systems

MIL-HDBK-781 Handbook for Reliability Test

Methods, Plans, and Environments for

Engineering Development, Qualification, and Production

2.2 Non-Government Documents

ANSI/NCSL Z540 Calibration Laboratories and

Measuring and Test Equipment

ASTM D 4956 Retro-reflective Sheeting for Traffic

Control

— 5 —

ISO 3411 Earth Moving Machinery - Human

Physical Dimensions of Operators and

Minimum Operator Space Envelope

SAE-AIR-1471 Torque Tightening Threaded Fasteners

SAE AS 50881 Aerospace Vehicle Wiring

SAE J377 Vehicular Traffic Sound Signaling

Devices (Horns)

— 6 —

3 SYSTEM REQUIREMENTS

3.1 Definition

The SAH is to be a highly maneuverable, low profile, towbarless, diesel powered aircraft handling vehicle designed to tow, turn and spot all Naval shipboard aircraft in the tight confines of the hangar bays aboard

CVN, LHA and LHD class ships while at sea. It will be capable of fitting underneath the aircraft, secure and lift its nose or tail landing gear, and maneuver the aircraft to/ from the hangar bay to the aircraft elevator in the conditions stated herein. It will also be capable of towing lighter aircraft and rolling stock via a tow bar.

The SAH in its operational environment will experience up to five degrees pitch/ roll, which relates to a horizontal acceleration of 0.31 g and vertical acceleration of 1.00 ±0.41 g (1.41 g's maximum~ 0.59 g's minimum). The SAH will be capable of meeting all requirements of this specification in the appropriate at-sea conditions. For the purposes of this document, the SAH is a system defined as the SAH unit including the remote control.

3.2 Characteristics

3.2.1 Performance Characteristics

3.2.1.1 Operator Control [SAH-FCN-0001]

The SAH shall have a remote control device to control SAH operations by a single person (operator) who must have an unobstructed view of the aircraft and SAHs engagement area when operating the SAH.

a. Remote Control Features [SAH-REQ-0024]

(1) The SAH remote control shall be capable of being operated wirelessly and via tethered cable.

(2) The remote control's speed and direction functions shall be of the return to center dead man type.

(3) The remote control shall be worn by the operator with the ability to tear away, preventing the

SAH from pulling the operator along with it.

(4) The SAH shall have provisions for the cable and remote control to be stored on the SAH.

b. Wireless Remote Control [SAH-REQ-0030]

(1) The remote control shall be operational on battery power alone for at least eight hours.

(2) The remote control shall have a battery charger that operates on 115 VAC and which can recharge a drained battery in less than four hours.

(3) The remote control shall be pair-able to a specific SAH, and shall have no adverse effect/interference when multiple SAHs are operated simultaneously side by side. The process of pairing a controller to a SAH shall be able to be performed by personnel trained as an operator.

c. Tethered Remote Control [SAH-REQ-0025]

(1) The remote control shall be capable of operating the SAH with a coiled type cable reaching up to

20 feet from the attached SAH.

(2) The remote control cable shall have a strain relief cord and have quick disconnect connectors on each end.

(3) When the cable is attached, the wireless capability shall be automatically disabled.

(4) The cable shall be capable of being driven over by the SAH without sustaining damage.

— 7 —

(5) The remote control shall operate with the cable attached when the remote control batteries are missing or discharged.

3.2.1.2 Draw Bar Pull [SAH-FCN-0002]

The SAH shall provide no less than 14,100 lbs DBP on dry level concrete in both forward and reverse directions with a 17,300 lb load held by the lifting mechanism. Ship motion has already been accounted for in the Draw Bar Pull requirement.

3.2.1.3 Lifting Capability [SAH-FCN-0003]

The SAH shall be able to lift a static load of at least 17,300 lbs.

a. Lifting/Attachment Mechanism Operational Characteristics [SAH-REQ-0003]

(1) The operator controlled lifting/attaching mechanism shall be capable of being raised and lowered without a load at speeds varying from zero to two inches per second to adjust to various sized aircraft landing gear.

(2) The lifting/attaching mechanism shall have positive control preventing disengagement of the nose/tail landing gear and not loosen under all operating conditions.

(3) The lifting/attaching mechanism shall prevent disengagement of the landing gear when raised off the deck regardless of operator control inputs or vehicle motion.

(4) The lifting/attaching mechanism shall not vibrate so as to make engagement to the landing gear difficult.

b. Lifting/ Attachment Mechanism Dimensional Characteristics [SAH-REQ-0004]

(1) The center of the lifting/attaching mechanism shall be located at the SAH's center of rotation.

(2) The lifting/attaching mechanism shall accommodate up to 10 degrees of horizontal misalignment of the landing gear to compensate for camber in the landing gear as it is turned by the SAH.

(3) If using axle pins to engage the aircraft, the lifting/attaching mechanism shall engage aircraft landing gears of widths varying from 10.5 inches to 32.25 inches, and have at least 1.0 inches of clearance on each side of the aircraft engagement point to facilitate alignment.

(4) If using axle pins to engage the aircraft, three different interchangeable pins shall be used. The pins shall interface the aircraft with the same dimensions identified in the following drawings:

1117AS242 and 1117AS243.

(5) If using axle pins to engage the aircraft, the SAH shall have provisions for the pins to be stored securely on the SAH.

(6) The lifting/attaching mechanism shall be able to lift the landing gear a minimum of 18 inches off the deck. If using pins engaged to the landing gear axles, the engagement centerline heights vary from 4.5 inches to 31 inches off the deck (this range includes the total lift height requirement).

c. Lifting/ Attachment Mechanism Material Strength [SAH-REQ-0005] The lifting/attaching mechanism shall be designed with a factor of safety of at least 3 to 1 to material yield strength under all expected loads in the operating environment as defined in Para 3.1.

d. Lifting/ Attachment Mechanism Hold Load in Operational Environment

[SAH-REQ-0006] The SAH shall be able to hold a 17,300 lb. lifted load in all operating environments (starting, accelerating, stopping and all turns considering operational sea state conditions) with no loss of lifted height.

e. Lifting/ Attachment Mechanism Dynamic Loads [SAH-REQ-0007]

— 8 —

(1) The SAH shall withstand the forces associated with dropping off and climbing onto a 1.5 inch high ledge at maximum towing speed with a 17,300 lb lifted load with no loss of lifted height.

(2) The SAH with a 17,300 lb. lifted load shall withstand the side forces associated with an instantaneous 90 degree turn while towing a 66,000 lb aircraft at maximum towing speed.

3.2.1.4 Speed Control [SAH-FCN-0004]

The SAH shall accelerate or decelerate upon command providing controlled movement at creeping speed both loaded and unloaded. Operator control shall be a speed-demand type system where control movement is proportional to speed.

a. Speed Capability [SAH-REQ-0008] The SAH shall perform the following requirements in the forward and reverse direction:

(1) The unloaded SAH shall be capable of 3 (+ 1/ -0) MPH.

(2) The SAH, with 66,000 lbs. in tow and 17,300 lbs. carried by the lift mechanism shall have a top speed of 2.5 (+/-0.5) MPH.

(3) The SAH, with 66,000 lbs. in tow and 17,300 lbs. carried by the lift mechanism shall be able to maintain a speed of 1.5 (+/ - 0.5) MPH while climbing a 5 degree incline.

3.2.1.5 Braking [SAH-FCN-0005]

The SAH shall stop under the control of the operator. When the controls are released (dead-man control), or the E-Stop button is pushed, the SAH shall meet the following requirements and not vary more than one foot from a straight line when stopped suddenly:

a. Towed Load Braking Requirement [SAH-REQ-0009] The SAH, while towing a 66,000 lb.

load (with 17,300 lbs. carried by the lift arms) at top speed, shall come to a complete stop within 2.0 feet when the operator controls are release or the E-stop button is pushed.

b. Unloaded Braking Requirement [SAH-REQ-0010] The SAH, with its max operational weight and no carried load, shall stop within 1.5 feet from its top speed when the braking system is applied.

3.2.1.6 Parking Brake [SAH-FCN-0006]

The SAH shall provide a parking brake that simultaneously locks all driven wheels.

a. Parking Brake Operation [SAH-REQ-0011] The parking brake shall be applied by means of a single control located on the SAH. If the parking brake is operated by a hand lever, it shall not exceed 18 inches in length from the pivot point and shall require no more than 30 pounds force to apply.

b. Parking Brake Hold on a Slope [SAH-REQ-0012] The parking brake shall be capable of holding the unloaded SAH in place on a 15 degree slope oriented at any direction to the vehicle’s centerline.

c. Parking Brake Skid Requirement [SAH-REQ-0013] When the unloaded SAH’s parking brake is actuated, the driven wheels shall skid on dry concrete when pulled with sufficient force .

3.2.1.7 Steering Control [SAH-FCN-0007]

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

— 9 —

a. Steering Alignment [SAH-REQ-0015] The operator shall be capable of steering the SAH

(without a load) in a straight line within +/- 0.5 foot over a distance of 100 feet at top speed in both forward and reverse directions.

b. Steering Maneuverability [SAH-REQ-0016] The SAH (without a load) shall be capable of traversing a figure 8 course consisting of a 30 foot diameter circle and a 15 ft diameter circle joined at their perimeters in either direction when traveling in forward or reverse directions in 35 seconds per lap. The SAH shall not stray beyond the confines of the figure 8 course during a timed lap.

c. Turning Radius [SAH-REQ-0017] The SAH shall be designed to have a zero turning radius measured at the center of the attachment point to aircraft’s nose or tail gear. The turning radius shall not deviate more than 3 inches when measured unloaded in both clockwise and counter clockwise rotation.

3.2.1.9 Lighting Control [SAH-FCN-0009]

Flood lights and running lights shall be provided with separate on/ off switches.

a. Lighting Protection [SAH-REQ-0026] All lights shall be adequately recessed or shielded to prevent damage.

b. Flood Lights [SAH-REQ-0027] The SAH shall be equipped with two red LED flood lights of at least 345 candelas each mounted and aligned to illuminate the area under the aircraft and the aircraft engagement mechanism, and at least one matching flood light mounted on other end of the unit (facing opposite direction from aircraft engagement mechanism).

c. Running Lights [SAH-REQ-0028] The SAH shall be equipped with four red LED running lights with at least 10 Candelas each located near the corners of the SAH.

3.2.1.10 Monitor/ Display Status [SAH-FCN-0010]

The SAH shall monitor and provide a display to the operator of various subsystem statuses as described herein. Monitors, switches, warning lights and controls shall be clearly visible in all day and night conditions including bright sunlight.

a. Monitor/Display Equipment Operating Hours [SAH-REQ-0132] The SAH shall monitor and display the equipment operating hours (engine run time). Total hours shall not reset if electrical power is lost.

b. Monitor/Display Fuel Level [SAH-REQ-0133] The SAH shall monitor and display the fuel level.

(1) A warning signal to alert the operator, such as a light, on the remote control shall be illuminated when the fuel level in the tank is down to 1/8th capacity and below.

c. Monitor/Display Battery Condition [SAH-REQ-0134] The SAH shall monitor and display the battery voltage level.

d. Monitor/Display Engine Temperature [SAH-REQ-0135] The SAH shall monitor and display the engine cooling system temperature.

(1) A flashing red warning light mounted in an easily visible location on the remote control shall be activated to specifically identify that the coolant temperature has surpassed the manufacturers recommended maximum.

e. Monitor/Display Oil Pressure [SAH-REQ-0136] The SAH shall monitor and display the instantaneous oil pressure.

— 10 —

(1) A flashing red warning light mounted in an easily visible location on the remote control shall be activated to specifically identify that the oil pressure has dropped to below the manufacturer’s recommended safe operating level.

f. Fault Warning Indicator [SAH-REQ-0137] The SAH shall monitor and display critical and non-critical faults.

(1) Flashing warning lights mounted in an easily visible location on the remote control shall be activated to specifically identify that a non-critical (yellow light) or a critical (red light) fault has occurred.

g. Warning Light Checkout [SAH-REQ-0138] The SAH shall provide a method to verify the warning lights are properly working.

h. Automatic Shutdown Systems [SAH-REQ-0139] The SAH shall have at least three automatic shutdown systems. One shall be activated by low engine oil pressure, one activated by high coolant temperature and one for low fuel to prevent running dry.

i. Parking Brake Indicator Light [SAH-REQ-0142] The SAH shall display a red warning light in an easily visible location on the remote control indicating the parking brake is actuated.

3.2.2 External Interface Requirements

a. Aircraft Interface [SAH-REQ-0018] The SAH shall be capable of lifting and lowering the aircraft's nose/tail landing gear and disengaging from it without contacting any surface of the aircraft at any approach/departure angle up to +/- 90 degrees port or starboard of its centerline. The aircraft engagement mechanism shall be compatible with the following aircraft when; the nose/tail landing gear oleo strut is normally serviced (exceptions will be made for H-60R and V-22 where the struts are extended 17" and 14" respectively to allow proper clearance): AV-8B, E-2C/D, F/A-18 (all variants), E/A-18G, F-35B/C, H-53E/K, H-60R/S, T-45 and V-22.

b. Aircraft Interface Dimensions [SAH-REQ-0019] The SAH shall interface with aircraft nose or tail landing gear. Further aircraft interface details are provided as Attachment (1) to this specification.

c. Deck Non-Skid [SAH-REQ-0020] The SAH shall be compatible with ship deck surfaces covered in non-skid per MIL-PRF-24667C. The SAH tires shall generate the traction required to prevent sliding while operating in the conditions identified in this specification.

d. Deck Allowable Load [SAH-REQ-0021] The SAH shall not exceed the deck loading limits defined below:

— 11 —

Figure 1 Hangar Deck load limits

e. Deck Allowable Load Capacity Reduction [SAH-REQ-0022]

(1) The load capacity curve does not account for the dynamic effect that ships motions have on equipment in a sea way environment. Therefore, ship motion affects must be applied to the equipment load (SAH/Aircraft landing gear combination) and contact patch (footprint) to determine the maximum load before comparison to or use with the deck capacity chart.

(2) The load limit curve (Figure 1) is intended to be used for single patch loads only. However, it is also used when there is a minimum of 7 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 2), shall be applied to the loads associated with the patch areas. For closely spaced adjacent patch areas, clear space less than 1/2 min patch dimension, and/or when there are three or more contact patches with 7 ft of each other, contact the government for guidance.

(3) The capacity charts are for design guidance only and use does not constitute or imply design approval by the Naval Technical Authority (NTA) or the Technical Warrant Holder (TWH).

— 12 —

Figure 2 Deck allowable load reduction factor

f. Jacks [SAH-REQ-0023]

(1) The SAH shall have at least four jacking points compatible with A-A-59545, Type II jacks. These points shall be on both ends of the unit and have chassis cutouts or features that provide a means for secure jacking aboard a moving ship.

(2) The SAH shall have at least four jack stand points that consist of chassis cutouts or pockets that are 6 inches square to accommodate ten ton jack stands and provide a means for secure support during ship motion. These points are to be independent from the jacking points and not impede access to components for maintenance actions.

g. Tow Bar Interface [SAH-REQ-0031]

(1) The SAH shall have a removable provision at 11 +/- 0.5 inches from the deck to interface with the lunette eye of the ALBAR Tow Bar (1479AS200-1).

(2) The tow bar shall be capable of rotating +/- 90 degrees from the centerline of the SAH without obstructions.

(3) The contractor shall determine the maximum draw bar pull for which the SAH with no load on the lift arms is capable and design the tow bar interface provision to meet this load. The minimum acceptable draw bar pull shall be no less than 3,070 lbs from the Tow Bar interface provision.

3.2.3 Transportability

a. Transportation [SAH-REQ-0029] The SAH shall be designed to withstand externally imparted vibration rigors of over the road, truck, and rail transportation as specified in

MIL-STD-810, Method 514.6 - Vibration and Method 526 - Rail Impact, without incurring damage and no degradation of performance as specified herein.

— 13 —

b. Aircraft External Transport [SAH-REQ-0032] The SAH shall be capable of being transported by external air Helicopter Sling Load (HSL) via the H-53 helicopter (single hook lift).

MIL-STD-913 is to be used for design guidance. This includes meeting the lifting/tiedown feature requirements of this specification, HSL testing and obtaining certification via the US Army Soldier

Systems Center (SSC), Natick, MA. The HSL certification process document is provided as

Attachment (2) to this document.

c. Towing the SAH [SAH-REQ-0034] (1) The SAH shall be capable of being towed and maneuvered using an ALBAR tow bar, P/N 1479AS200-1, and tow tractor after manually disengaging the brakes, drive and steering systems.

(2) Provisions for attachment of the tow bar (using the tow bar's pins) shall be designed to accept the force imposed by the tow bar when pushing, pulling or maneuvering (including ship motion factors) without permanent damage or deformation.

(3) After manual disengagement of the drive system, brakes and steering it shall be possible to tow the SAH at 3 MPH for 1,000 ft. Towing shall not cause damage, premature wear of mechanical parts, or loss of performance to the SAH.

3.2.4 Physical Characteristics

a. Dimensions [SAH-REQ-0035] The overall physical size of the SAH shall be limited to 148"

L x 81"W and the height as described in the 3D model provided in Attachment (1). Attachment (1) does not address ground clearance. The length dimension limitation excludes the remote control and tow bar interface provision.

b. Ground Clearance [SAH-REQ-0036] The SAH with a 17,300 lb load on the lifting arms shall have a ground clearance greater than 1.5 inches.

c. Unit Weight [SAH-REQ-0037] The fully fueled operational SAH shall weigh less than

15,000 lbs.

d. Approach and Departure Angle [SAH-REQ-0038] The unloaded SAH shall be capable of traversing the ramp identified in Figure 3:

Figure 3 GSE Shop Ramp

3.2.5 System Quality Factors

a. Reliability Requirements [SAH-REQ-0093] The SAH shall have a Mean Time Between

Failure (MTBF) of not less than 375 hours in a Naval Sheltered (NS) environment. The requirement applies to the integrated system, including both hardware and software. Failure consists of the SAH not being capable of performing its mission.

b. Maintainability Requirements [SAH-REQ-0094]

1) The SAH shall have a Mean-Time-To-Repair (MTTR) of 2.5 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:

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i. Fault detection

ii. Fault isolation

iii. Removal and replacement of the failed component

iv. Calibration and/or alignment (if required)

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

vi. 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

3.2.5.1 Fault Detection and Isolation

a. Fault Detection and Isolation Provisions [SAH-REQ-0095]

Built-In-Test (BIT) shall automatically detect a minimum of 95% of faults which prevent the SAH 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 SAH, and other standard support equipment/tools, the fault isolation performance shall be:

Ambiguity </= 3SRAs 95% of detected faults

Ambiguity </= 2SRA 90% of detected faults

Ambiguity = 1SRA 85% of detected faults

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. False Alarm Rate [SAH-REQ-0096] The fault detection provision shall not result in more than 20 hours of unnecessary maintenance per SAH per year.

c. Fault Reporting/ Fault Indication [SAH-REQ-0097] Alarm indication shall be such that it is readily noticeable and facilitates 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. Fault display, due to size, may be located on the SAH rather than on the remote control with warning lights on the remote to indicate the automated critical and non-critical faults.

3.2.6 Environmental Conditions

Performance of the SAH as described in this specification shall not be degraded when exposed to the environmental conditions listed herein.

a. Operating Temperatures [SAH-REQ-0041] The SAH shall operate continuously in temperature conditions ranging from -20° F to 125° F.

— 15 —

b. Cold Starting of Diesel Engine [SAH-REQ-0042] The diesel engine shall start in cold weather (-20° F), without the use of ether.

c. Storage Temperatures [SAH-REQ-0043] The SAH shall withstand storage temperature conditions ranging from -40° F to 140° F.

d. Relative Humidity [SAH-REQ-0044] The SAH shall operate continuously in an environment with up to 95% relative humidity.

e. Salt Fog [SAH-REQ-0045] The SAH 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. Blowing Rain [SAH-REQ-0046] The SAH shall operate continuously in blowing rain consisting of four inches per hour rain fall with 40 mph winds.

g. Blowing Sand [SAH-REQ-0047] The SAH 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.

h. Blowing Dust [SAH-REQ-0048] The SAH 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.

i. Storage in Wind [SAH-REQ-0049] The SAH in storage conditions shall withstand wind up to 90 MPH.

j. Shipboard Vibration [SAH-REQ-0050] The SAH shall be designed to resist the vibrations associated with operation aboard CVN, LHA, and LHD class ships per MIL-STD-810, Method

528.1, TYPE 1.

k. Shipboard Shock [SAH-REQ-0051] The SAH shall meet the shock requirements of

MIL-S-901 for Grade A, heavyweight equipment.

l. Explosive atmosphere [SAH-REQ-0052] The SAH shall be capable of operating in a fuel-air explosive atmosphere without causing ignition as described in MIL-STD-810, Method 511.5, Procedure I.

3.2.6.1 Electromagnetic Radiation

a. Electromagnetic Interference (EMI) [SAH-REQ-0039] The SAH shall meet the requirements of MIL-STD-461 Table V, RE102, RS103, CE 106, CS 114 and CS 116 for flight deck environments.

b. Electromagnetic Environment (EME) [SAH-REQ-0040] The SAH shall meet the EME requirements of MIL-STD-464, Paragraph 5.3, Table 1 for flight deck environments.

c. Hazards of Electromagnetic Radiation to Ordnance (HERO) [SAH-REQ-0141] The intensity of the EME produced by the SAH shall not exceed the Maximum Allowable Environments

(MAE) detailed in Figures 2-1 and 2-2 of NAVSEA OP 3565 Volume 2 when operated near electrically initiated ordnance within its intended concept of operation (CONOP) in ship hangar bays and aircraft elevators.

3.2.7 Design Features

a. Frame and Body [SAH-REQ-0062]

(1) The main frame of the SAH shall be of sufficient strength and rigidity to prevent visual distortion when one corner of the frame is raised six inches.

(2) The body shall provide protection to all components against physical damage and the environment.

— 16 —

(3) All enclosures or recesses shall be provided with drains in order that fluids will not accumulate in them.

(4) Protection shall be provided for equipment lines, hoses and wires by routing the lines and wires close to structural members where they can be secured if necessary and by providing suitable protection or clearance where the pass through bulkheads. A monocoque or unibody design is permitted provided it has adequate rigidity as described above and provisions to secure lines, hoses and wires are provided

(5) The stress level, under the maximum static rated load at any point in the structure, shall be limited to a level that provides a factor of safety of three (3) against permanent deformation. This includes the Tow Bar Interface provision (paragraph 3.2.2.g [SAH-REQ-0031]) and associated components at the maximum draw bar pull capability of the unloaded SAH.

b. Top Surface [SAH-REQ-0063]

(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) There shall be no louvers or screens on any top surface of the body.

(3) The horizontal top surfaces shall be covered with black non-skid safety walk conforming to

MIL-W-5044, (painted on).

c. Door and Panel Security [SAH-REQ-0064] All hinged doors shall be provided with devices to secure them in the open and closed positions such that they will not be damaged by jet blast or ambient winds. Stops or bumpers shall be installed so that the doors (or stops), do not mark or scratch the paint work. All door hinges shall be stainless steel and removable (not welded). Doors or panels shall be provided to facilitate access to components for maintenance and servicing of (as appropriate) hydraulic fluid, fuel, and engine coolant. All latches shall be non-keyed.

d. Emergency Stop [SAH-REQ-0074]

(1) Emergency stop buttons shall be located on the remote control and each side of the SAH easily accessible to anyone walking with the vehicle.

(2) Activating the emergency stop button shall cause the SAH to bring the vehicle and aircraft to a stop in a straight line within 2 feet from top speed without use of the aircraft’s brakes.

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

(4) The position of the lifting mechanism, either loaded or unloaded, shall not be affected by activating the emergency stop

e. Start Assist Receptacle [SAH-REQ-0075] The SAH shall be equipped with an external power receptacle (NAVAIR Drawing 328AS289) for recharging of the batteries and engine starting with an external power source of 24 to 28 volts DC. This receptacle shall also supply electrical power should other support equipment require jump starting. Receptacle shall be mounted so as not to protrude from the overall dimensions of the unit.

f. Keyless Starting Switch [SAH-REQ-0076] The SAH shall have a keyless starting switch.

g. Starting Batteries [SAH-REQ-0077]

(1) Batteries for starting the diesel engine shall be spiral cell technology batteries manufactured by

Optima Battery Inc., division of Johnson Controls Inc.

(2) Unit shall employ an onboard system to keep batteries at optimum charge at all times.

— 17 —

(3) Battery enclosures shall be vented.

h. Ignition Switch Electrical Disconnect [SAH-REQ-0078] The ignition switch shall electrically disconnect the batteries when switched to the “Off” position to prevent potential drain on batteries.

i. Starter Motor Circuit Cutout [SAH-REQ-0079] A starter motor circuit cutout shall be incorporated to prevent damage to the starter or ring gear once the engine is running.

j. Motor Controller [SAH-REQ-0080] If using an electric drive method, the motor controller must have the following features:

(1) The motor control unit shall be designed and sealed to prevent maintainers from being able to alter the SAH’s performance parameters such as acceleration, braking rate, etc.

(2) The motor controller, motor, and operator controls shall be designed to facilitate pin to pin trouble shooting allowing the maintainers to isolate a failure to one of the three components.

k. Electric Drive Motor(s): [SAH-REQ-0081] If using an electric drive, the drive motor(s) shall be brushless DC or AC type and shall have an integral spring applied electrically released motor brake to prevent motor creep at low voltage and provide smooth acceleration.

l. Magnetic Drain Plugs [SAH-REQ-0088] Magnetic drain plugs shall be installed in the engine crankcase, the hydraulic tank and fuel tank.

m. Emergency Aircraft Disengage [SAH-REQ-0089]

(1) The SAH shall be capable of being manually disengaged from the nose or tail landing gear when the SAH is inoperable. The emergency disengagement system is to be easily accessible without removal of any access panels and not require the use of tools.

(2) It shall take no more than one minute for two personnel to disconnect the SAH from the nose or tail landing gear using the emergency disengagement system.

n. Drive/Steering System Manual Disengage [SAH-REQ-0090]

(1) The SAH drive system, brakes and steering shall be able to be manually disengaged/ released to facilitate being easily towed and/or pushed when it 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.

o. Lifting/Tiedown Rings [SAH-REQ-0091]

(1) Eight swivel ring assemblies conforming to MIL-STD-209 shall be provided. At least four of these rings shall be for the dual purpose of lifting and tying down the SAH and be securely attached near each corner of the unit. This includes provisions for crane lift, helicopter sling loading and tiedown requirements. The additional rings may be dual purpose or only for tie down purposes.

(2) All rings shall be compatible with TD-1B shipboard tiedown assemblies and located so that when tied to the deck, the tiedown assemblies will not contact the SAH.

(3) The SAH shall be capable of being stowed, tied down in the hangar bay with TD-1B tiedown chains, in at sea storm conditions defined as: Ah = 0.900 g; Az = 1.000 +/- 0.549 g

p. Wires and Cables [SAH-REQ-0100] Wires and cables shall be sorted and supported in a manner to reduce the possibility of damage due to abrasion and snagging during maintenance and operation. Wires passing through holes in sheet metal shall be protected by grommets. Sufficient

— 18 — clearance shall be maintained between wiring and heat generating parts to prevent damage to wire insulation.

q. Horn [SAH-REQ-0128] An electric horn, per the requirements of SAE J377, shall be provided with its control button located on the operator’s remote control panel.

3.2.7.1 Nameplates and Product Markings

a. Nameplates and Product Markings [SAH-REQ-0053] 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 [SAH-REQ-0054] The SAH 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 4 Identification Plate

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c. Instruction Plates [SAH-REQ-0055] Instruction plates shall conform to MIL-DTL-15024, Type H, Style III. These plates shall be suitably located in view of the operator and contain clear, concise instruction for the operation of all controls.

d. Transportation Instruction Plate [SAH-REQ-0056] The transportation instruction plates conforming to MIL-DTL-15024,Type H, Style III, shall be inscribed with 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.

e. Modification Plate [SAH-REQ-0057] 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 [SAH-REQ-0058]

(1) The retro-reflective material shall be applied in accordance with MIL-M-81807 along the extreme perimeter of the equipment 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 [SAH-REQ-0059] 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 at least one inch characters

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

(4) Serial number, with at least one inch characters

(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) with at least one inch characters for fuel.

(7) Jacking and jackstand positions

(8) Pintle (tow bar interface provision [SAH-REQ-0031]) capacity

h. Warranty Sticker [SAH-REQ-0060] 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 [SAH-REQ-0061] 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.

3.2.7.2 Power Plant

a. Diesel Engine [SAH-REQ-0065] The SAH shall utilize a Tier III diesel engine; A National

Security Exemption for the SAH to allow 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

— 20 — certificate from the OEM. The internal combustion engine must have a crankcase ventilation system that will capture blow-by oil mist and not allow oil dripping.

b. Fuel Types [SAH-REQ-0066] 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 (MJL-DTL-83133) jet fuel

- F-24 (NATO) jet fuel

- Diesel fuel (A-AA-52557)

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

c. Fuel Filters [SAH-REQ-0067]

(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 [SAH-REQ-0068]

(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 corrosion-resistant 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 [SAH-REQ-0069]

(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 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.

f. Fuel Tank Capacity [SAH-REQ-0140] The SAH fuel tank shall be sized to accommodate 48 aircraft moves without refueling. An aircraft move is defined as a distance of 250 feet, towing a

66,000 lbs load with 17,300 lbs held by the Lifting/ Attachment Mechanism, and an unloaded distance of 250 feet.

g. Exhaust System [SAH-REQ-0070]

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

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

(3) The tail pipe shall be secured to withstand vibration and emit exhaust gases at least 5 to 10 degrees down from a horizontal direction.

(4) The exhaust system shall be routed clear of all fluid lines and fuel and electrical system components. If routed through areas where leakage of oil, grease, or fuel could occur, the exhaust system shall be shielded from direct contact by such leakage.

h. Engine Cooling System [SAH-REQ-0071]

(1) The cooling system shall have the capacity to prevent the coolant temperature from exceeding the engine manufacturer’s temperature limit while operating at maximum load for extended periods of time.

(2) Coolant filler caps shall be painted gloss white, color number 17875 of FED-STD-595.

(3) The coolant to be used and the tank capacity shall be stenciled adjacent to the filler cap in gloss black color number 37038 of FED-STD-595.

i. Engine Coolant [SAH-REQ-0072] Engine coolant shall meet the requirements of commercial item description A-A-52624A. Type I (ethylene glycol) is preferred. The mixture shall provide protection for operating and storage temperatures as specified in this document.

j. Water and Coolant Servicing Provision [SAH-REQ-0073]

(1) Coolant filler caps of the pressure type shall be painted gloss white, Color No. 17875 of

FED-STD-595.

(2) The coolant to be used and the tank capacity shall be stenciled adjacent to the filler opening.

(3) Coolant level shall be able to be checked without removing the filler cap.

(4) The filler neck shall have a minimum diameter of 1-1/2 inches.

3.2.7.3 Hydraulic System

a. Hydraulic System Fittings [SAH-REQ-0082] The SAH’s hydraulic system, if so equipped, shall have the flareless type fittings conforming to SAE J 514.

b. Hydraulic Tank [SAH-REQ-0083] If using a hydraulic system, the hydraulic tank shall:

(1) be constructed of stainless steel

(2) be equipped with a drain plug at the lowest point in the tank

(3) have a filler cap painted in accordance with SAE ARP1247 paragraph 3.13.11.4 and be permanently…