6k_Low_Profile_-_NAVSUP_WSS_PD-511_Dated_25_July_2013.pdf

[INCH-POUND]

NAVSUP WSS PD-511

25 July 2013

SUPERSEDING

A-A-59498

13 OCTOBER 1999

PURCHASE DESCRIPTION

TRUCK, FORKLIFT, DIESEL ENGINE DRIVEN,

DS SAFETY RATED, FOR SHIPBOARD USE

1. SCOPE

1.1 Scope. This purchase description (PD) covers the requirements for three types of diesel powered forklift trucks (hereafter referred to as trucks) for shipboard use. This document shall be used in conjunction with Purchase Description NAVSUP WSS-TD-1.

1.2 Intended Use. Each type of truck described herein is intended to be used aboard ships for the purpose of stacking, un-stacking, and transporting palletized loads, some of which may consist of ordnance.

2. CLASSIFICATION. The trucks shall be of the following classifications:

TYPE 2 – 6,000# Capacity, Solid Rubber Tire, Low Profile TYPE 4 - 15,000# Capacity, Pneumatic Rubber Tire TYPE 5 - 20,000# Capacity, Pneumatic Rubber Tire

3. SALIENT CHARACTERISTICS

3.1 Configuration. In addition to the other requirements stated in this PD, each truck must meet the characteristics listed in Table 1.

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: Naval Supply Weapon Systems Support, Code 8341, MHE Division, 5450 Carlisle Pike, Mechanicsburg, Pennsylvania, 17055-0788.___ _

FSC 3930

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

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TABLE 1. SALIENT FEATURES

CHARACTERISTIC

TYPE 2

TYPE 4

TYPE 5

CAPACITY @ 24" LC (RATED

LOAD)

6000#

15,000#

20,000#

TIRE TYPE

SOLID

PNEUMATIC

PNEUMATIC

# TIRES - DRIVE

LIFT HEIGHT (MIN.)

92"

220"

220"

COLLAPSED MAST HT. (MAX.)

68"

128"

145"

FREE LIFT HT (MIN.)

33.5"

31"

6"

FORK THICKNESS

2"

2.5"

2.5"

FORK WIDTH

8"

7"

FORK LENGTH

40"

48"

72"

FORK SPACING (MIN SPREAD)

44"

58"

58"

FORK SPACING (MAX.

TOGETHER)

14"

20"

22"

TRUCK OVERALL LENGTH

(MAX. WITH FORKS)

154"

240"

260"

TRUCK OVERALL WIDTH

66"

96"

98"

TRUCK OVERALL CAB

HEIGHT(MAX)

70"

115"

120"

TRUCK WEIGHT (NO LOAD)

(MAX.)

12,800#

28,800#

35,500#

RIGHT ANGLE TURN (MAX.)

180"

260"

275"

UNDERCLEARANCE (MIN)

3"

LONGITUDINAL STABILITY

(STACKING)

8%

4.6 DEG

3.5%

2 DEG

4%

2.3 DEG

TABLE 1. SALIENT FEATURES (Continued)

CHARACTERISTIC

TYPE 2

TYPE 4

TYPE 5

LONGITUDINAL STABILITY

(TRAVELING)

27%

15.1 DEG

18%

10.2 DEG

18%

10.2 DEG

LATERAL STABILITY -

(STACKING)

8%

4.6 DEG

10%

5.7 DEG

10%

5.7 DEG

LATERAL STABILITY

(TRAVELING)

40%

21.8 DEG

DECK LOADING (MAX.)

8,400#

9000#

10,500#

TRUCK SPEED MAX. W/ LOAD

7 MPH

10 MPH

10 MPH

SIDESHIFT EACH SIDE OF

CENTER

4"

SLOPE ASCENSION (WITH

LOAD)

22%

12.4 DEG

TILT - FORWARD

3 DEG

TILT - REARWARD

6 DEG

10 DEG

10 DEG

3.2 Design. Truck shall be designed for the lifting capacity (rated load) at the specified load center, measured from the vertical face of the forks, and to the specified full lift height.

No adjustments or deration to the lifting capacity will be permitted for lift height, side shifters or any other factor specified herein. Design of trucks and all components therein shall insure safe operation under marine service conditions. Truck shall be designed to permit selection and operation of travel, lift, steering, tilt, and side shift separately, simultaneously or combinations thereof.

3.2.1 Quality. Trucks shall be manufactured in accordance to the applicable requirements of ISO 9001:2000, Quality Management Systems - Requirements.

3.3 Safety. The truck shall conform to the applicable requirements of ANSI-ITSDF B56.1-

2009, UL 558, and OSHA Standards in effect at the time of issue of the solicitation.

Truck shall bear the UL stamp of approval for "DS" safety rated trucks.

3.3.1 Safety Certification. The truck shall bear the UL stamp of approval as specified. In addition, the contractor shall provide to the contracting officer satisfactory evidence that the truck furnished under this specification meets or exceeds the requirements of 3.4.

Acceptable evidence of meeting these requirements shall be certified test reports from paa4114 Sticky Note not supposed to be ANSI/ITSDF B56.6-2011, right?

Underwriter's Laboratories.

3.4 Engine. The engine shall be diesel powered, capable of operating on the following fuels:

Naval Distillate Fuel (F-76) conforming MIL-F-16884, Aviation Turbine Fuel JP-5 (F-

44) conforming to MIL-DTL-5624, and JP-8 (F-34) conforming to MIL-DTL-83133.

The engine shall meet all U.S. Environmental Protection Agency Regulations and U.S.

Federal Laws in act at time of manufacture, California Emission Standards in act at the time of manufacture.

3.5 Fuel system. The capacity of the fuel tank shall insure not less than 8 hours continuous operation during the reliability test specified herein. The tank shall be equipped with a safety filler cap assembly, which shall incorporate a self-closing cap, screw-locking device for cap, removable strainer, and provision for padlocking. Fuel caps for diesel engine driven trucks shall be painted green. The filler-neck opening shall not be less than 2 inches in diameter and shall be located such that the tank can be filled from a 5-gallon can. The fuel filler tube shall also accommodate a commercial size dispenser nozzle. The fuel tank shall be equipped with a drain plug at the lowest point of the tank. The fuel tank shall be protected by position or otherwise from external damage.

3.6 Exhaust system. The engine exhaust system shall be designed to prevent entry of rain into the exhaust system and to prevent accumulation of water and condensed vapors.

Exhaust gases shall be discharged vertically above the operator's compartment or at the rear or side rear of the truck within the plan outline of the truck. Exhaust gases shall not be discharged in a path that would interfere with the operator or by-standers. All components of the system shall be replaceable with the use of hand tools.

3.7 Cooling System. The truck shall be equipped with a cooling system fan that discharges air away from the operator.

3.8 Transmission. A power shifted transmission shall be furnished. Transmission in forward and reverse shall provide either variable speed or single speed range for trucks of 6000 pound capacity and two speed range for trucks greater than 6000 pound capacity.

Transmissions shall provide for positive inching control of truck (throughout the entire range of engine speed) in the forward and reverse directions.

3.9 Electrical system. The truck shall have either a 12 volt or 24 volt electrical system. Each electrical circuit shall be protected from electrical overload with circuit breakers IAW J553. Fuses are permitted. All electrical circuitry, controls, instrumentation, and components shall be protected in order to prevent any type of moisture or water damage.

3.9.1 Starting system. Truck shall be provided with an interlock, or other means, in the starting system to prevent energizing the starter motor except when the directional control lever is paa4114 Sticky Note just confirming it's acceptable to have either 12 or 24 volt, correct? I know we have changed this in the past.

in the neutral position and when the engine is not running.

3.9.2 Alternator. The alternator shall have output capacity sufficient to meet the electrical load required by the engine and to support the complete truck electrical system and accessories furnished with the vehicle plus a 25 percent reserve capacity measured at maximum engine rpm. The alternator shall charge the battery at engine low idle speed and shall maintain battery charge at full electrical load.

3.9.3 Battery. The battery shall be a maintenance free battery. The battery box shall provide storage of the battery while allowing a minimum of 3” clearance between the battery and the box. A battery restraint is required in the battery box.

3.10 Lift system. The lift system shall consist of all components necessary for the lifting, fork positioning, tilting, and sideshift operations of the truck. The brake system and drive assembly shall not be a part of the lift (hydraulic) system. The lift system shall provide for controlled lowering of the rated load in the event of failure or damage to components utilized within the lift system.

3.11Hoses. Permanently attached hose fittings are acceptable as original hose assemblies only when the permanent fitting and hose design are such that a replacement hose assembly fitted with field attachable fittings will fit in place of the original hose assembly. Hoses in accordance with SAE J517 100R7 or 100R8 are not permitted.

3.12Steering. Power steering shall be furnished. The steering system must be operable with a dead engine. In the event of power steering failure or engine failure, and without rated load, steering shall be operable with a force not to exceed 50 pounds.

3.13Upright and Carriage Assembly. Upright (mast) shall be of the telescopic roller type with sufficient strength and rigidity to withstand, without permanent deformation, stresses induced by capacity loads specified herein. Cross members of the mast structure, with the forks in the traveling position, shall not interfere with the operator's horizontal or downward line of sight directly to the front of the vehicle.

3.14Forks. Fork dimensions and spacing shall be as specified on the applicable military specification sheet. Fork spacing dimensions shall be measured from the outer edges of the forks. Fork spacing on trucks of 6,000 pounds capacity shall be adjustable laterally without the use of hand tools and shall be attached to the fork carriage in accordance with ANSI-ITSDF B56.11.4. Fork thickness shall not exceed 1/2 inch at the tips and the end taper shall be not less than 14 inches long. Taper shall be on the underside of the forks.

Folding forks shall be furnished on trucks of 6,000 pounds capacity. The forks shall be hinged or pivoted near the heels and shall be capable of being folded back manually against the fork upright and backrest. A manually operated locking device shall hold the forks in the upright position. Trucks of 15,000 pound capacity and above shall have forks attached to the fork carriage in accordance with Industrial Truck Association Recommended Practices. When the operator is seated, at least the tip of one fork shall be visible at all lift heights.

3.15Fork Positioner. Trucks of 15,000 pounds capacity and above shall be provided with hydraulic forks positioners.

3.16Fork Sideshift. All trucks shall be equipped with a hydraulically operated side shift attachment.

3.17Load backrest. A metal backrest, removable without disturbing any other component, shall be provided. Load backrest shall be flush (plus 0 inches, minus 3/8 inches) with the forward vertical surface of the forks. In conjunction with fork and hanger design it shall provide a vertical rear guard at least 48 inches high measured from the load carrying surface of the forks and at least equal to the width of the carriage. It shall not obstruct operator's visibility. A positive means or stops shall be provided to prevent the fork tines from slipping off the fork carriage when the backrest is removed. The removable backrest may be eliminated if fork and carriage assembly will provide protection equal to the above.

3.18Wheels and tires. Wheels and tires shall be selected from sizes, load, and speed ratings listed in the Year Book of the Tire and Rim Association. Split rims (wheels) are not permitted.

3.18.1 Solid or Cushion Tires. Drive and steer tires shall have non-directional lug type tread.

Smooth type tread is not acceptable. The tread design shall provide for gripping cleats across the entire width of the tire. The lug shall be a minimum of 3-1/2 times wider than the groove. The gripping cleats shall be such that the centerline and point of all cleats starting from one edge shall meet the dividing line between a set of cleats starting from the opposite edge. Drive and steer tires shall be siped. There shall be two sipes on each lug of the drive tire and one sipe on each lug for the steer tire.

3.18.2 Wheels for Pneumatic Tires. Trucks specified for shipboard use shall not be equipped with split rim wheels.

3.18.3 Pneumatic Tires. Tires shall be pneumatic, high pressure, tube or tubeless type furnished with all-purpose tread.

3.19Service brakes. The truck shall be equipped with four-wheel service brakes and a parking brake. Service brake system shall be independent of the hydraulic (control) system and power train. A dual (split) redundant hydraulic or air system shall be provided to independently activate the front and rear brakes to prevent complete brake failure in the event of failure in either circuit. The brake system shall be equipped with a visual or audible warning indicator which shall be energized due to a loss of hydraulic or air pressure in either brake circuit. The service brakes shall function with either a dead or stalled engine. A brake pedal force of not more than 100 pounds and not less than 50 pounds shall stop the truck with and without the rated load as specified herein. Brake linings, shoes, or pads shall contain no asbestos.

3.20Parking brake. A mechanically actuated parking brake shall be provided. Parking brake shall be independent of the service brake's hydraulic system.

3.21Deadman control. Trucks shall be provided with a deadman control, such that upon removal of the operator's weight from the seat, the deadman control shall apply the drive wheel brakes and also automatically return the transmission to neutral when the engine is running. On mechanically activated transmissions, the directional control lever shall be automatically returned to the neutral setting whenever the control lever is positioned at any setting other than neutral. Visual examination shall confirm the transmission control lever has been reset to neutral. On electrically activated transmissions, the control lever need not be returned to neutral but a flashing indicator light located on the instrument panel shall alert the operator the transmission is in neutral regardless of the position of the transmission control lever. A nameplate located adjacent to the flashing light shall instruct the operator he must first reset the transmission control lever to neutral prior to selecting a directional mode. In no case shall either a mechanical or electrically operated transmission return to any directional mode automatically with the return of the operator's weight to the seat. A manual release or override of the deadman control shall be furnished.

3.21.1 Mechanically activated transmission. On mechanically activated type transmissions, the directional control lever shall be automatically returned to the neutral setting whenever the control lever is positioned at any setting other than neutral. Visual examination shall confirm the transmission control lever has been reset to neutral.

3.21.2 Electrically activated transmissions. On electrically activated transmissions, the control lever need not be returned to neutral but a flashing indicator light located on the instrument panel shall alert the operator that the transmission is in neutral regardless of the position of the transmission control lever. The flashing light shall only terminate when the transmission control lever directional mode selection has been completed and not on return of the operator's weight to the seat. A nameplate located adjacent to the flashing light shall instruct the operator he must first reset the transmission control lever to neutral prior to selecting a directional mode.

3.22Towing device. A ring or pin type towing device shall be provided at the rear of the

Sticky Note do we need to add the below like it says in PD-506?:

(a) Service brakes shall stop the truck within the specified limits when tested in accordance to ANSI/ITSDF B56.6-2011.

(b) Service brakes shall stop the truck within a distance of 10 feet maximum when the truck is traveling down a 45% (24 degrees) at a speed of 5 mph minimum in the reverse direction.

(c) Service brakes shall restrain the truck on a 45% (24 degrees) minimum slope immediately after the service wheel brakes have been immersed in water for a period of ten minutes minimum.

(d) Service brakes shall stop the truck within a distance of 5 feet maximum when the truck is traveling at a speed of 5 mph minimum and with a dead engine.

truck. It shall not protrude beyond the path followed by the rear end of the truck when making a turn of minimum turning radius. The towing device is strictly for towing a forklift out of the way when mechanically inoperative. Forklift is not designed for normal towing operations.

3.23Slinging and Tiedown Attachments. Truck shall be equipped with a minimum of four slinging and tiedown attachments conforming to MIL-STD-209, Class 1, 2 or 3 for Type II or III equipment, excluding air transportation requirements. Also tiedown attachments shall meet the requirements of a Grade A item in Type A, HI (High-Impact) Shock as specified in MIL-S-901.

3.24Operator's overhead guard. The truck shall be equipped with an overhead guard in accordance with ANSI-ITSDF B56.1. Whenever the collapsed mast height is lower than the overhead guard height, the over head guard shall be removable with the use of hand tools. The ROPS/FOPS shall be capable of being removed without limiting the forklift functionality, to include lighting. A non-removable guard is permitted when the overhead guard height the same or lower than the collapsed mast height. Handles shall be provided on the front and rear overhead guard posts to assist the operator in accessing the operator’s seat.

3.25Controls. All switch and lever type controls shall be provided with position markings

(decals are not acceptable) either at the switch, or lever, or in the case of the directional speed controls, on a diagram visible to the operator. The distance from the near edge of one knob to the near edge of an adjacent knob or other surface shall be a minimum of 1-1/2 inches (40 mm). Use of commercial truck operating controls is acceptable. All load handling control symbolic markings shall be in accordance with ISO 3287.

3.25.1 Electrical Switch. A three position keyless switch, or a combination of two switches, with a safety lockout feature to prevent accidental engagement of the starter when the engine is running shall be provided on the truck. Engine operation shall terminate when switch is turned to the off position.

3.26Instruments. Truck shall be furnished with the following instruments which shall be flush-mounted on the instrument panel and shall be capable of being read by the operator while in his normal sitting operating position: electrical system monitor, engine oil pressure monitor, engine coolant temperature monitor, hour meter which totals engine operating hour only, fuel gauge. Gauges, indicator lights and meters shall be constructed to be moisture and weather resistant. Gauges shall be internally lighted. Whenever indicator light instruments are furnished, means shall be provided to check operation of the light. Gauges shall have internal lighting which shall be controlled by a single on-off switch. Each knob, button and switch’s function shall be identified with a label or placard.

3.27Floodlights. Each truck shall be equipped with three horizontally and vertically adjustable floodlights. Two floodlights shall be mounted on the mast facing forward and one floodlight shall be mounted on the rear of the overhead guard facing rearward. Each floodlight shall be furnished with three sets of lenses. Color of lenses shall be clear, red and yellow. Lenses shall be stored in a pocket located on the back of the operator's seat.

Installation of floodlights shall not interfere with operator visibility and shall not interfere with removal of the overhead guard (if applicable). When removable overhead guards are utilized means to disconnect stoplight electrical circuit without the use of hand tools shall be provided.

3.27.1 Light Switches. One on-off switch shall be provided for operation of the mast mounted floodlights and one on-off switch for the operation of the overhead guard floodlight.

3.28Stoplight. One automotive, red, reflector type, combination stoplight and tail lamp of not less than 15 candle power and 3-candle power respectively shall be mounted on the truck counterweight or on the rear of the overhead guard. When removable overhead guards are utilized means to disconnect stoplight electrical circuit without the use of hand tools shall be provided. The stoplight shall not operate when the electrical switch is in the off position.

3.29Horn. Truck shall be equipped with an electric horn. The horn shall have a minimum decibel rating of 105dB.

3.30Seat. The truck shall be provided with a cushioned seat and backrest, which shall be adjustable, at a minimum, forwards and backwards.

3.31Weighing device. Trucks shall be equipped with a weighing device to measure the amount of weight on the forks. The device shall be capable of measuring a minimum weight of 100 pounds and a maximum weight equal to the rated capacity of the truck plus 300 pounds. Weighing device shall be capable of being adjusted for 25% tare. A bourdon tube dial indicator shall be provided. The entire instrument and connections shall be moisture and weather resistant. The weighing device shall be capable of withstanding the pressure caused by placing 150-percent of truck rated load on the forks without sustaining damage. The read-out shall be readable by the operator when in the seated position. The dial shall be not less than 8.5 inches in diameter and the increments shall be marked in 50-pound increments. The indicating pointer shall be capable of 360 degrees rotation for full-scale reading.

3.32Identification Plates. The truck shall be equipped with identification plates conforming to

A-A-50271, Composition C, with information as specified herein.

3.32.1 Identification marking. Each truck shall be identified with an identification plate. The identifying data to be applied to the plates shall be in accordance with ANSI-ITSDF B56.1 in addition to the following: truck lifting capacity and load center, lift height, model number, serial number, contract number, gross vehicle weight (with rated load), USN registration number, delivery date, technical manual stock number, shipping weight (with forks and without rated load), cube dimension, name or stamp of government inspector, warranty expiration, High Shock test date, and manufacturer's name and address.

3.32.2 Instruction, warning, and caution plates. Each truck shall be equipped with instruction, warning, and caution plates prominently located and describing any special or important procedures to be followed in operating, lifting, and servicing of the truck or its components.

3.32.3 Shipping data plate. Shipping data plate shall indicate the silhouette of the forklift in transport position showing the center of gravity and the location and capacity of the lifting and tiedown attachments. Wheel loading information may be included on shipping data plate.

3.32.4 Wheel loading plate. Each truck shall be equipped with a wheel loading plate. As a minimum the plate shall have the following information:

Wheel loading (no load on forks) Drive wheels (each wheel) pounds Steer wheels (each) pounds

Wheel load (rated load on forks) Drive wheels (each wheel at maximum sideshift) pounds Steer wheels (each) pounds

3.32.5 Safety rating plate. Each truck shall be equipped with a safety designation plate. As a minimum, the plate shall indicate the truck manufacturer's name, truck model number, safety designation (Type DS), Underwriters Laboratories registration or index number assigned to the inspected truck and date of inspection.

3.32.6 Lubrication Tag. The truck shall be equipped with a lubricant/fluid list installed in a visible location to indicate which lubricant/fluid has been used in each component or system.

Trucks for shipboard use shall operate as specified herein when lubricated with standard military lubricants and hydraulic fluids listed in MIL-HDBK-267. No other lubricants/fluids are permitted for shipboard trucks.

3.32.7 Cold Start Instructions. Diesel engine driven trucks shall be equipped with a cold start instruction plate. Plate shall instruct the operator as to the steps required to utilize the truck's cold start system.

3.33 Vehicle marking. Each truck shall be marked as specified herein. All markings shall be painted in black enamel block letters and numbers or decals.

3.33.1 Vehicle Weight. The truck's weight without load shall be painted on each side of the truck in 2 inch high numerals and 3/4 inch high on mast cross bar in view of operator. Example:

Truck weight - 13000 pounds.

3.33.2 Safe working load. Safe working load (capacity) of the truck shall be 3 inch high numerals located on each side of mast and 3/4 inch high on mast cross bar in view of operator.

Example: SWL 6000 pounds

3.33.3 Registration number. Assigned USN registration number for each truck shall be 3 inches high located on each side and on rear of truck. Example: USN 13-12345

3.33.4 Tire pressure. For pneumatic tired trucks, the tire pressure for each tire shall be 1 inch high numerals located near the applicable tire. Example: TIRE PRESSURE 120 PSI

3.33.5 Safety rating. Markers indicating the safety designation of truck shall be applied on each side of the truck. These markers shall be in accordance with UL 558.

3.33.6 Supplementary markings. Supplementary marking and load handling symbols as specified in ISO 3287 are required.

3.33.7 Slinging and tiedowns. Slinging and tiedown markings shall be in accordance with MIL-STD-209, except the shipping data plate shall conform to A-A-50271.

3.33.8 Safety warning. Safety warning information shall be 2 inch high letters, located as follows:

3.33.8.1 Safety warning. "NO RIDERS" shall be located on rear of mast.

3.33.8.2 Safety warning. "NO SMOKING" shall be visible when operator is in normal operating position.

3.33.9 Fuel type. Fuel type shall be 1 inch high letters and located near fuel tank filler.

Example: DIESEL FUEL ONLY

3.33.10 Shipboard marking. Truck shall be identified with the words "SHIPBOARD USE APPROVED", located on each side of truck, in 1-1/2 inch high letters.

3.33.11 Structural testing. Trucks which successfully pass the weight test shall be identified on each side of truck with 1-1/2 inch high letters:

Example:

STRUCTURALLY TESTED

(month / year) BY (manufacturer's name)

3.33.12 Paint marking. Each side of truck shall be marked as follows with 1-1/2" high letters:

Example:

PAINTED WITH LEAD/CHROMATE FREE PAINT

(month / year) BY (manufacturer)

3.33.13 Brake marking. Following statement shall be on truck using 1" high letters:

Example:

NON-ASBESTOS BRAKE LININGS USED.

REPLACEMENTS SHALL BE NON-ASBESTOS.

3.34 Treatment and painting. Trucks shall be painted with not less than one coat of base primer and one finish coat. Paints or coatings used shall be lead and chromate free, recommended for use around salt air environments. The primer coat shall be a corrosion inhibiting type. The top or finish coat shall be compatible with the base/primer coating. The topcoat shall be resistant to impact and abrasion, urethane or powder coated type, applied to a dry film thickness of 3 mils minimum. The finish color shall be 13538 in accordance with FED-STD-595. Primer and finish coats shall be applied in accordance with normal commercial practices to assure complete coverage. The finish coat, when dry, shall be a smooth even surface, free from runs, sags, peels, chips, blisters, and areas of thin film or no film. Surfaces of components and assemblies of the truck, not normally painted with a finish coat, shall be cleaned and protected in accordance with good commercial practice. Lift chains, sprockets, rollers, plastics, fabric hoses (except hydraulic hoses) and drive belts shall not be painted. Paint must be kept off working surfaces where interference with working parts would result. Engine accessories, such as radiator, drive belts, instruments, chrome plating and lift chains shall not be painted and shall be adequately protected or masked from overspray. Paint application shall meet applicable standard listed for either urethane or powder coated type application, (ASTM D7803, ASTM A153, or urethane paint manufacturer's recommended procedures).

3.35 Fluid Service Access. All fluid levels must be accessible without removal of panels. This includes both provisions for the checking and topping off of fluid levels. There shall be no leakage of any fluid while the vehicle is positioned in any stability or slope configuration. All fluid reservoirs exceeding 15 quarts shall be fitted with sampling valves, excluding fuel and coolant reservoirs. The valves shall be accessible without removal of panels.

3.36 Workmanship. The truck shall perform operations that are specified herein without permanent deformation, breakage of connections, malfunction, or component interference caused by incorrect workmanship. All parts of the truck before and after painting shall be clean and free from sand, rust, dirt, fins, pits, spurs, risers, scale, flux, and other harmful extraneous material.

Edges and surfaces exposed to operating and maintenance personnel shall be smooth and rounded to the extent that a hazardous surface does not exist.

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

3.38 Performance. In addition to the following performance characteristics, truck shall meet all dimensional and performance requirements listed in Table 1.

3.38.1 Lifting and lowering speed. Speed of lifting rated load shall be 55 feet per minute through the entire lift range. Speed of lowering of forks shall be not less than 50 feet per minute without rated load and not more than 100 feet per minute with rated load over the entire distance from maximum fork height to ground level. The hydraulic system shall provide for lowering of the rated load at a rate of 30 feet per minute maximum in the event of hydraulic fluid loss and/or failure of or damage to the hydraulic system.

3.38.2 Drift of lift assembly. The lift assembly shall be capable of holding the rated load at the maximum lift height for not less than two minutes with not more than 1.75 inches of vertical drift and not more than one degree of rotational drift from the vertical.

3.38.3 Overload. The truck shall be capable of sustaining 300 percent overload for a minimum of ten minutes. (Front axle support and rear axle tiedowns are required.)

3.38.4 Resistance to saline atmosphere. The truck shall be designed to withstand the corrosive effects of saline atmosphere without any loss or deterioration of performance, loss of mobility of parts, harmful corrosion, evidence of paint chipping and flaking and an inability to disassemble parts for service or repair. All components within the electrical system shall remain operative.

3.38.5 High (High-Impact) shock requirement. The truck shall be designed to operate as specified herein when subjected to Type "A" High Shock as a Grade A item in accordance with

MIL-S-901.

3.38.6 Noise limits. The sound level at the operator's station shall not exceed 85 dB(A) maximum.

3.38.7 Deck loading. Truck individual wheel loading with rated load and forks at each paa4114 Sticky Note should we add "The truck shall be capable of meeting the requirements indicated in MIL-STD-810 "?

maximum sideshift position shall not exceed the weight listed on Table 1. The minimum dimension measured across the bearing area of each individual tire shall not be less than 5-1/2 inches under the wheel loading specified herein. In no case shall deck loading exceed 250 psi.

3.38.8 Electromagnetic interference characteristics. The truck shall conform to the radiation and susceptibility EMI requirements of MIL-STD-461.

3.38.9 Weight testing. Each truck shall be capable of sustaining 150 percent of the rated load without damage to the truck in the operational mode.

3.38.10 Operating Temperature. The engine shall start within 5 minutes and the truck shall operate as specified herein within 15 minutes after engine start in any ambient temperature from 0o F to plus 120o F.

3.38.11 Rain. The truck shall start within 5 minutes and operate as specified herein when subjected to a rainfall of not less than 4 inches per hour for a period of one hour without malfunction or damage to any component.

3.38.12 Reliability. Truck shall be capable of operating for 500 hours without the need for unscheduled maintenance.

3.38.13 Sideshift Attachment. The sideshift attachment shall be capable of side shifting the rated load without deformation to the attachment, truck carriage or upright. Sideshift mechanism shall operate forks either side of center while carrying rated load a minimum of 4 inches (plus or minus 1/4 inch).

3.38.14 Maintainability. One man shall be able to accomplish following maintenance operations, except as noted, in the time specified using common tools and special tools (if any) furnished with the truck:

3.38.14.1 Remove, replace, and adjust all engine driven belts - 3/4 hour. Exclude engine-timing belt(s).

3.38.14.2 Remove and replace alternator - 1/2 hour.

3.38.14.3 Remove and replace regulator - 1/2 hour.

3.38.14.4 Remove and replace all filters, screens, and strainers in all hydraulic systems - 1/2 hour.

3.38.14.5 Drain engine coolant, Remove and replace engine coolant system hoses and thermostat and refill system - 1 hour.

3.38.14.6 Drain engine lubricating oil, remove and replace oil filter elements, and refill crankcase - 1/2 hour.

3.38.14.7 Remove and replace fuel filter elements and drain water separator - 1/4 hour.

3.38.14.8 Disconnect battery cables, remove and replace battery, and reconnect battery cables - 1/2 hour.

3.38.14.9 Drain transmission oil, remove and replace all filter elements and strainers, and refill converter and transmission - 1/2 hour.

3.38.14.10 Remove and replace starter - 1 hour.

3.38.14.11 Bleed and adjust brakes and refill master cylinder or accumulators (two men) - 3/4 hour.

3.38.14.12 Remove, read, and replace fluid level dipstick or conduct a visual inspection - 2 minutes each.

3.38.14.13 Disassemble and service air induction system including replacement of air filter - 1/2 hour.

3.38.14.14 Reset circuit breaker or replace fuses- 2 minutes each.

3.38.15 Maintenance. Navy maintenance personnel shall be capable of performing all repairs to forklift without manufacturer’s intervention. All required special tools, to include diagnostic software, shall be included in procurement and must be acquired under separate contract line item in the contract.

3.39 Rust Protection. All fasteners and hydraulic hose fittings shall have grade 4 rust preventative applied to them to inhibit the formation of rust.

3.40 Cowling. A cowling shall be provided for the protection of the operator’s legs which extends from the floorboard to the instrument panel.

4. REGULATORY REQUIREMENTS.

4.1 Recovered materials. The manufacturer is encouraged to use recovered materials to the maximum extent practical, in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR). However, used, rebuilt or remanufactured components, pieces and parts shall not be incorporated in the forklift truck.

5. QUALITY ASSURANCE PROVISIONS.

5.1 Product Conformance. The products provided shall meet the salient characteristics of this purchase description, conform to the producer's own drawings, specifications, standards, quality assurance practices, and be the same product offered for sale in the commercial market. The government reserves the right to require proof of such conformance.

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

6. PACKAGING.

6.1 Preservation, packing, and marking. Preservation, packing, and marking shall be in accordance with the manufacturer's standard commercial practice unless otherwise specified in the contract or purchase order.

7. NOTES.

7.1 Acquisition requirements. Acquisition documents must specify the following:

a. Title, number, and date of this specification

b. Issue of DODISS to be cited in the solicitation, and if required, the specific issue of individual documents referenced (see section 8.1)

c. When first article inspection is required (see 7.3)

d. When vehicle design speed is other than as specified (Table 1)

7.2 Technical manuals. The requirements for technical manuals shall be considered when this specification is applied on a contract. The technical manual shall be created based on Purchase Description NAVICP-PD-21861 dated 29 May 2012, Manual, Technical, Material Handling Equipment. In addition, technical manuals are required based on military specifications, and standards that have been cleared and listed in DOD 5010.12- L, Acquisition Management Systems and Data Requirements Control List (AMSDL) must be listed on separate Contract Data Requirements List (DD Form 1423), which is included as an exhibit to the contract. The technical manuals must be acquired under separate contract line item in the contract.

7.2.1 Technical Manual Verification Review. The technical manual verification review will be conducted by the government to validate that the vehicle's final technical manual accurately reflects the vehicle configuration, general information, operating instructions, safety rating, preventative maintenance, repair and overhaul, illustrated parts breakdown and parts list index. The vehicle will be operated only to the extent required by the technical manual to ensure that each section of the manual is accurate. Repair and overhaul operations will not be conducted, but will be reviewed for clarity. The illustrated parts breakdown and parts list index will be reviewed to the extent possible without major disassembly of the vehicle. The manual review shall be conducted after successful completion of first article inspection. The vehicle shall be available for review for a period of fifteen consecutive calendar days. In the event the technical manual does not accurately reflect the vehicle, a written list of discrepancies will be included in the pre-final technical manual review comments. One vehicle shall be furnished. The contractor shall provide notification of truck shipment to the contracting officer and the Naval facility a minimum of 20 days prior to shipment. Technical manual verification review shall be conducted not later than 14 days after approval of First Article Inspection.

Location of review shall be:

Naval Surface Warfare Center Indian Head Division Detachment Picatinny Building 458, Whittemore Ave.

Picatinny Arsenal, New Jersey 07806-5000 Attn: Bob Monroe

7.3 First article. When first article inspection is required, the contracting officer should provide specific guidance to manufacturer whether the item should be a preproduction sample, a first article sample, a first production item, a sample selected from the first production items, a standard production item from the contractor’s current inventory (see 3.2) and the items to be tested as specified in NAVSUP WSS-TD-1. The contracting officer should also include specific instructions in acquisition documents regarding arrangements for examinations, approval of first article test results, and disposition of first articles. Invitations for bids should provide that the Government reserves the right to waive the requirements for samples for first article inspection to those bidders offering a product which has been previously acquired to be tested by the Government, and that bidders offering such products, who wish to rely on such production or test, must furnish evidence with the bid that prior Government approval is presently appropriate for the pending contract. Bidders should not submit alternate bids unless specifically request to do so in the solicitation.

7.4 MIP/MRC - Develop and deliver Maintenance Index Pages (MIPs) and Maintenance

Requirement Cards (MRCs) in accordance with MIL-STD-3034 and MIL-P-24534.

Delivery for approval shall be in electronic format [New PMS Editor (NPE)] to the ISEA address listed below. Developers for the MIPs/MRCs are to be (minimum) Level 2 certified. MIP/MRC must be acquired under separate contract line item in the contract.

Authorized MIP/MRC developers:

DRS (Chesapeake VA), Dan Nunn (757) 312-9300

EG&G (Norfolk VA) Dale Hopper (757) 858-4784

AT&T (San Diego CA) Stan Owens (619) 209-4605

ISEA:

Director

Naval Surface Warfare Center Indian Head Division Detachment Picatinny Building 458, Whittemore Ave.

Picatinny Arsenal, New Jersey 07806-5000 Attn: Bob Monroe

7.5 Provisioning. Provisioning Technical Documentation (PTD) shall consist of digital technical manual(s) as per NAVICP-PD-21861 and a complete digital parts list which includes parts pricing. This shall be furnished as specified in the contract.

7.6 Parts. When ordering spare parts or repair parts for the equipment covered by this specification the contract should state that such spare parts and repair parts should meet and/or exceed the same requirements and quality assurance provisions as the parts used in the manufacture of the equipment. Packaging for such parts should also be specified.

7.7 Sub-contracted material and parts. The packaging requirements of referenced documents listed in section 2 do not apply when material and parts are acquired by the contractor for incorporation into the equipment and lose their separate identity when the equipment is shipped.

8. Source of documents.

8.1 Federal and Military Specifications and Standards are available from the DODSSP, Standardization Documents Order Desk, Bldg 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.

MIL-S-901: Shock Tests, H.I. (High Impact) Shipboard, Machinery, Equipment and Systems; Requirements For

MIL-DTL-16884: Fuel, Naval Distillate

MIL-DTL-5624: Turbine Fuel, Aviation Grades JP-4, JP-5, and JP-5/JP-8 ST

MIL-STD-810: Environmental Test Methods and Engineering Guidelines.

MIL-DTL-83133: Turbine Fuels, Aviation, Kerosene Types, NATO F-34(JP-8) and NATO F-35.

FED-STD-595: Colors

MIL-STD-209: Slinging and Tiedown Provisions

MIL-STD-461: Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-1474: Department of Defense Design Criteria Standard, Noise Limits

A-A-50271: Plate Identification

A-A-52550: Pintle Assembly, Towing Manual Release 18,000, 40,000 and 100,000 lbs capacity

NAVSUP WSS- TD-1: NAVICP-M Testing Requirements For Truck, Lift, Fork, Diesel, Shipboard

MIL-HDBK-267: Guide for Selection of Lubricants and Hydraulic Fluids for Use in Shipboard Equipment

MIL-P-24534: Military Specification Planned Maintenance System: Development Of Maintenance Requirement Cards, Maintenance Index Pages, And Associated Documentation

MIL-STD-3034: Reliability-Centered Maintenance (RCM) Process

8.2 OSHA documents are available from Superintendent of Documents, U.S. Government

Printing Office, and Washington, D.C. 20402.

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) 29 CFR,

Chapter XVII, Part 1910 Occupational Safety and Health Standards

8.3 ANSI-ITSDF documents are available from Industrial Truck Standards Development

Foundation, 1750 K Street NW, Suite 460, Washington DC 20009

ANSI-ITSDF B56.1-201: Safety Standard for Low Lift and High Lift Trucks.

ANSI-ITSDF B56.11.4-2005: Hook-Type Forks and Fork Carriers for Powered Industrial

Forklift Trucks.

8.4 SAE documents are available from the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, Pennsylvania 15096.

SOCIETY OF AUTOMOTIVE ENGINEERS HANDBOOK (SAE Handbook)

SAE J517: Hydraulic Hose

SAE J695: Turning Ability and Off Road Tracking – Motor Vehicles

8.5 Tire and Rim Association documents are available from the Tire and Rim Association, Inc., 175 Montrose West Avenue, Suite 150, Copley, Ohio 44321.

8.6 UL documents are available from Underwriters Laboratories Inc., 333 Pfingsten Road, Northbrook, Illinois 60062.

UL 558: Internal Combustion Engine Powered Industrial Trucks

8.7 ISO documents are available from American National Standards Institute, 1899 L St NW, 11th Floor, US-Washington, DC 20036

ISO 3287: Powered Industrial Trucks - Symbols for Operator Controls and Other Displays

ISO 9001:2000, "Quality Management Systems - Requirements"

8.8 NAVSUP WSS Department of the Navy, Naval Supply Weapons System Support, Code 8341, 5450 Carlisle Pike, P.O. Box 2020, Mechanicsburg, PA 17055-0788

NAVICP PD-21861: Purchase Description Manual, Technical, Materials Handling Equipment

8.9 AWS documents are available from American Welding Society (AWS), 8669 NW 36 Street, # 130, Miami, Florida 33166-6672

AWS D1.1/D1.1M:2006, Structural Welding Code - Steel

AWS D1.3-98, Structural Welding Code - Sheet Steel

AWS D1.6:1999, Structural Welding Code - Stainless Steel

8.10ASTM documents are available from ASTM International, 100 Barr Harbor Drive, PO

Box C700, West Conshohocken, PA, 19428-2959 USA

ASTM D7803 - 12 Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Powder Coating

ASTM A153 / A153M - 09 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

9. Supersession data. This purchase description replaces Commercial Item Description A-A- 59498 dated 13 October 1999.

Custodian: Preparing Activity:

Navy-SA Navy-SA