Testing_document_-_NAVSUP_WSS-TD-1 _Dated_25_July_2013.pdf

NAVSUP WSS-TD-1

25 July 2013

SUPERSEDING

NAVICP-TD-1

11 November 1999

NAVSUP WSS TESTING REQUIREMENTS FOR

TRUCKS, LIFT, FORK, DIESEL, SHIPBOARD

1.0 PURPOSE. The purpose of this document is to provide testing requirements for the verification of shipboard and ordnance handling forklift trucks. This document shall be used in conjunction with Purchase Description NAVSUP WSS PD-511.

2.0 VERIFICATION.

2.1 Classification of inspections. The inspections requirements specified herein are classified as follows:

(a) First article inspection (see 2.2)

(b) Post test inspection (see 2.3)

(c) Quality conformance inspection (see 2.4)

(d) Government first article inspection (see 2.5)

2.2 First Article (first produced) Test and Inspection. When a first article inspection is required

(see contract), the truck(s) shall be the first production item. The first article shall consist of one unit, except at the contractor's option, a second unit may be used for the High Shock and saline atmosphere tests. Prior to examination and test of the truck(s) the following shall be performed:

(a) A schedule of maintenance shall be furnished which shall be followed during all testing of the first produced truck. A list of special tools, if any, required to perform this maintenance shall also be provided.

(b) Truck shall be serviced with oils and greases specified herein and designated for use in the ambient temperature at which the test will be conducted.

(c) Truck break-in shall be performed when required.

2.2.1. Safety Examination. Safety examinations shall be conducted to ensure that the trucks furnished meet or exceed the safety requirements of UL 558, Type DS. Acceptable evidence of meeting these requirements shall be a certified report(s) from Underwriters

Laboratories indicating that the trucks conform to the requirements of UL 558.

2.2.2. Tests. The truck shall be subjected to the tests marked "X" in Column 1 of Table I. Test conditions and schedule shall be as follows:

(a) Unless otherwise specified herein, tests shall be conducted at the ambient temperature and climatic conditions existing at the place of test. Only that maintenance established by the contractor and submitted as a maintenance schedule prior to commencement of tests shall be performed during the tests.

(b) Tests may be conducted in any order desired except the reliability test shall be the last test conducted.

(c) Rated load is defined as load equivalent to an unrestrained cube with overall dimensions twice the required load center dimension. Rated load weight tolerances shall be plus or minus one percent.

(d) Load center is defined as the horizontal and longitudinal distances from the intersection of the horizontal load carrying surfaces and vertical load-engaging faces of the forks to the center of gravity of the load. Tolerance for dimensions shall be plus or minus 1/8 inch.

(e) Paragraph references in the following table and paragraphs refer to Purchase

Description NAVSUP WSS PD-511.

Table I. First Article Test Schedule

First Post Test NAVSUP WSS Test Test

PD-511

Produced Test Para. Para Number 1 2 3 4 5 6 x x Lifting speed 3.38.1 2.2.2.1 1 x x Lowering speed 3.38.1 2.2.2.1 1 x Right angle turn Table 1 2.2.2.2 2 x x Speed Table 1 2.2.2.3 3 x Underclearance Table 1 2.2.2.4 4 x x Slope ascension Table 1 2.2.2.4 4 x Parking brake 3.20 2.2.2.4 4 x Deadman control 3.21 2.2.2.4 4 x Upright tilt Table 1 2.2.2.5 5 x Collapsed mast height Table 1 2.2.2.6 5 x Lift height Table 1 2.2.2.6 5 x Free lift height Table 1 2.2.2.6 5 x Sideshift Table 1 2.2.2.6 5 x x Lift Assembly Drift 3.38.2 2.2.2.7 6 x Overload 3.38.3 2.2.2.8 7 x x Service brakes 3.19 2.2.2.9 -x Inching control 3.8 2.2.2.10 8 x Tire loading 3.38.7 2.2.2.11 9 x Deck loading Table 1 2.2.2.11 9 x Reliability 3.38.12 2.2.2.12 10 x Stability Table 1 2.2.2.13 -x Overhead guard 3.24 2.2.2.14 -x Slinging & tiedown 3.23 2.2.2.15 -x E.M.I. 3.38.8 2.2.2.16 -x Saline atmosphere 3.38.4 2.2.2.17 -x Truck weight Table 1 2.2.2.18 -x Starting system 3.9.1 2.2.2.19 -x High shock 3.38.5 2.2.2.20 -x Noise 3.38.6 2.2.2.21 -x Truck configuration Table 1 2.2.2.22 -x Fork spacing & visibility Table 1 2.2.2.22 -

2.2.2.1. Lift and lowering speeds. Test the truck in accordance with Test Method No. 1. Failure to conform to the requirements of 3.38.1 shall constitute failure of this test.

2.2.2.2. Right angle turn. Test the truck in accordance with Test Method No.2. Failure to conform to the requirements of Table 1 shall constitute failure of this test.

2.2.2.3. Speed. Test the truck in accordance with Test Method No. 3. Nonconformance to Table

1 shall constitute failure of this test.

2.2.2.4. Slope ascension, parking brake, deadman controls and underclearance. Test the truck in accordance with Test Method No. 4. Nonconformance to Table 1 shall constitute failure of this test.

2.2.2.5. Upright tilt. Test truck in accordance with Test Method No. 5. Nonconformance to

Table 1 shall constitute failure of this test.

2.2.2.6. Maximum lift height, collapsed mast height, free lift height, sideshift. Test the truck in accordance with Test Method No. 5. Failure to conform to the requirements of Table 1 shall constitute failure of this test.

2.2.2.7. Drift. Test the truck in accordance with Test Method No. 6. Nonconformance to 3.38.2

2.2.2.8. Overload. Test the truck in accordance with Test Method No. 7. Nonconformance with the requirements of 3.38.3 and Table 1 shall constitute failure of this test. Failure is defined as permanent deformation, fractures, broken welds and leakage in the hydraulic system. This requirement does not include the hydraulic pump, the hydraulic relief valve and the weighing device.

2.2.2.9. Service brakes. Test the truck stopping distance in accordance with the tests indicated in

ANSI-ITSDF B56.1. Nonconformance with the requirements of ANSI-ITSDF B56.1

2.2.2.10. Inching. Test the truck in accordance with Test Method No. 8. Nonconformance with the requirements of 3.8 shall constitute failure of this test.

2.2.2.11. Tire and deck loading. Test the truck in accordance with Test Method No. 9.

Nonconformance with requirements of 3.38.7 and Table 1 shall constitute failure of this test.

2.2.2.12. Reliability. Truck shall be tested in accordance with Test Method No. 10. The reliability test shall be conducted on a continuous basis during each operating 8 hour day (minimum). Testing shall be conducted at the rate of 20 to 25 circuits per hour (minimum). The 2000 circuits must be completed without any failures. If failure(s) occur before completion of 2000 circuits, the failure(s) must be corrected and test restarted beginning at the first circuit. Nonconformance to the requirements of 3.38.12 are defined as follows:

(a) Any malfunction which cannot be remedied by adjustment, repair or replacement action by contractor personnel using contractor tools and parts within 30 minutes.

(b) The totaled time of malfunctions exceeds 5% of the time required to complete the specified number of circuits.

(c) Failure to commence operation, cessation of operation or degradation of performance capabilities specified herein.

(d) Damage to the truck by continued operation such as fluid leaks, overheating or an internal component failure of the engine, transmission, axles, brakes, differential and hydraulic pump.

(e) Personnel safety hazard.

(f) Truck overturn or instability which results in either the steer or drive wheel losing contact with the ground for more than five seconds.

1. Only routine maintenance as prescribed by the contractor prior to the test is permitted.

2. Record the reason and amount of time involved for each truck stoppage or malfunction, including refueling, during the reliability test.

2.2.2.13. Stability. Test the truck in accordance with the test methods indicated in ANSI-ITSDF

B56.1. The stability requirements indicated on Table 1 shall supersede ANSI-ITSDF B56.1 stability requirements. Nonconformance with the requirements of ANSI-ITSDF B56.1 and Table 1 shall constitute failure of this test.

2.2.2.14. Overhead guard strength. Test the truck in accordance with the tests indicated in

ANSI-ITSDF B56.1. Nonconformance with the requirements of ANSI-ITSDF B56.1

2.2.2.15. Slinging and tiedown attachments. Measure slinging and tiedown clearances and test the truck in accordance with tests indicated in MIL-STD-209. Nonconformance to 3.24 and the requirements of MIL-STD-209 shall constitute failure of test.

2.2.2.16. Electromagnetic interference characteristics. For radiated emissions, procedure RE101 shall be used with limits shown in Figure RE101-2 over a frequency range of 30Hz to 100 kHz. Procedure RE102 shall be used with limits shown in Figure RE102-1 over a frequency range of 10kHz to 18 GHz.

For susceptibility to electric fields, procedure RS101 shall be used with the limits shown in Figure RS101-1 over a frequency range of 30Hz to 100kHz. Procedure RS103 shall apply with a frequency range from 2MHz to 18GHZ at a limit level of 200 volts/meter.

The truck shall be tested in accordance with MIL-STD-461. Acceptable evidence of meeting this requirement shall be a certified test report(s) from an independent testing laboratory acceptable to the government (see contract). Nonconformance with the requirements of MIL-STD-461 shall constitute failure of this test.

2.2.2.17. Saline atmosphere. The truck shall be prepared and tested in accordance with

MIL-STD-810, Method 509.5, Salt Fog. Any evidence of non-compliance with 3.38.4 shall be cause for rejection of the truck. Pursuant to Method 509.5, the following details are designated:

(a) Test duration: Exposure period shall be 24 hours of salt fog exposure followed by 24 hours drying for a minimum of 5 wet and 5 dry periods.

(b) Configuration: All surfaces of the truck, including the exposed surface of each piston rod, shall be cleaned and exposed to salt fog and the drying. The rod(s) of the tilt, mast (free lift cylinder), and of the side shift cylinder(s) shall be at full extension.

Components such as bearings and lift chains which are permanently lubricated during service use shall be lubricated in accordance with instructions of supplier prior to test.

Individual electrical components may be tested separately instead of with the entire truck.

(c) Cyclic conditions: Not required.

(d) Salt solution concentration: 5 percent +/- 1%.

(e) Additional guidelines: Visual inspections after 24, 72, and 168 hours of drying time but, no washing or operation is permitted until the examination following full exposure and drying period is completed. Truck shall be dried at room temperature, for a total of 168 hours, while loosely covered with a sheet of clear plastic to retard drying and allow visual inspection.

2.2.2.18. Truck weight. Truck weight shall be determined. Nonconformance with requirements of Table 1 shall constitute failure of this test.

2.2.2.19. Starting system. Start the truck engine within the time limits specified herein by energizing the starter motor switch with the transmission control lever in the neutral position. Release starter switch for a minimum of five (5) seconds, and attempt to reactivate starter switch while engine is operating. Attempt to start the engine with the transmission control lever in each position other than neutral. Any evidence of starter motor engagement shall constitute nonconformance to 3.9.1 and shall constitute failure of this test.

2.2.2.20. High Shock test. One first article truck shall be tested by the contractor in accordance with MIL-S-901. Acceptable evidence of meeting this requirement shall be a certified test report(s) from an independent high shock testing laboratory acceptable to the government (see contract). Prior to actual test, contractor shall submit a formal procedure to be used during the high shock test for approval. Procedure shall indicate applicable documents, test requirements, description of test, hardware configuration, preparation for testing, visual inspections, initial operational tests, evaluation of damage, shock test report, definition of failure, cause for rejection, completion of shock testing and post shock examination and post operational tests. Operational tests shall include lifting/lowering speed, acceleration, vehicle speed, slope ascension, under-clearance and stopping distance. Pursuant to 6.1 of MIL-S-901, the following ordering data shall apply to the test truck which shall be mounted on the Floating Shock Platform during the test and to the trucks furnished by the supplier:

(a) Shock tests: HI (High-Impact); Shipboard Machinery, Equipment and Systems, Requirements For", MIL-S-901.

(b) Issue of DODISS shall be the issue in effect on the date of invitation for bids or request for proposals.

(c) Grade A shock proofness required.

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

(e) Type A test.

(f) The truck is deck mounted.

(g) The truck is base mounted.

(h) The truck has unrestricted orientation.

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

(j) Catergories: Heavyweight

(k) The truck shall not be operated during the shocks, but it shall be operated briefly after each shock, to show lifting, lowering, drive wheels jacked up and rotating forward and reverse, sideshift operation and steering.

(l) Following the explosion of the depth charge at 20-foot (6 m) standoff, the truck shall comply with (k). Failure of the truck to comply with (k) or permanent deformation of any component preventing operation of truck shall be regarded as failure of the truck to meet the High Shock requirements indicated in 3.38.5.

(m) Acceptance authority is:

Naval Supply Weapon Systems Support, Code 8341, 5450 Carlisle Pike, P.O. Box 2020, Mechanicsburg, PA 17055-0788

2.2.2.21. Noise level measurement. The maximum steady state noise level shall be measured at the operator's station (microphone located no more than 6 inches from operator's approximate ear location) and at one meter from the perimeter of the truck. Noise level measurement shall be in accordance with MIL-STD-1474 with engine operating at maximum (no load) governed speed and at the speed required for the rated brake horsepower necessary to lift the rated load. Nonconformance to 3.38.6 shall constitute failure of this test.

2.2.2.22. Truck Configuration, fork spacing and fork visibility. Truck overall width, length, height, fork size, fork spacing and fork visibility shall be determined and recorded.

Measurements exceeding the dimensions indicated on Table 1 and the inability to see the tip of at least one fork at all lift heights shall constitute nonconformance to 3.14 shall constitute failure of this test.

2.3. Post tests. Upon successful completion of tests listed in 2.2.2, the truck shall be subjected to the tests marked "X" in column 2 of Table I. Nonconformance with performance requirements specified herein shall constitute failure.

2.4. Quality conformance examination and tests.

2.4.1. Tests. Each production truck shall be tested as follows:

Test Test Test

Paragraph Method

(a) Lift speed, Lowering speed 2.2.2.1 1

(b) Slope ascension, Parking 2.2.2.4 4 brake, Deadman controls,

(c) Service brakes 2.2.2.9 ANSI-ITSDF B56.1

Failure of any test shall be cause for rejection.

2.4.2. Weight testing. Each truck shall be tested for conformance to the requirements of 3.38.9.

Position the truck at rest on a smooth level surface, the mast vertical and the forks 6 inches above the ground. Secure truck as necessary to prevent truck overturn. With crane or another forklift truck place the 150 percent test load on the forks such that the center of mass of the test load is on the truck's centerline and at the rated load center. Let the 150 percent test load on the truck for ten minutes minimum. Remove load and restraints and visually inspect the forks, mast and other structural components for cracks, elongation, fluid(s) leakage, permanent deformation, fractures or failures. Failure is defined as any evidence of cracks, elongation, fluid leakage, permanent deformation, fractures or failure.

2.5. Government first article inspection. When a Government first article inspection is required (see contract), the Government will conduct a user review onboard a marine vessel prior to first article inspection as specified per 2.5.1.

2.5.1. User review test. Not required.

2.5.2. Technical manual verification review. The technical manual verification review will be conducted by the Government to validate that the truck's final technical manual accurately reflects the truck configuration, general information, operating instructions, safety rating, preventative maintenance, repair and overhaul, illustrated parts breakdown and parts list index. The truck will be operated only to the extent required 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 truck. The manual review shall be conducted after successful completion of first article inspection. The truck shall be available for review for a period of fourteen consecutive calendar days. Government review will be conducted in accordance with instructions in the contract or purchase order. In the event the technical manual does not accurately reflect the truck, a written list of discrepancies will be included in the pre-final technical manual review comments.

TEST METHOD NO. 1

LIFTING SPEED

LOWERING SPEED

1. Test Course: Level paved surface.

2. Test Apparatus:

(a) Tape measure.

(b) Timing device

3. Test Procedure:

PART I LIFTING SPEED

(a) Position truck on test course and record the time in seconds required to raise the rated load to maximum lift height using a timing device. Record the difference between maximum lift height and the height of the forks in the fully lowered position. Repeat the test three times and record the lifting speed in feet per minute. The test result shall be the average of the three tests.

PART II LOWERING SPEED

(a) Position truck on test course and record time to lower rated load at maximum speed (full open valve) to one foot height. Record the difference between maximum lift height and the one foot height. Repeat the test three times and record the lowering speed in feet per minute. The test result shall be the average of the three tests.

(b) Repeat operation (a) without rated load.

(c) Raise the rated load to maximum lift height with the mast in the vertical position. No personnel shall be located under or in front of the rated load for the next step. Cut or disconnect a hydraulic line that supplies pressure to the main lift cylinder and record the time for the rated load to reach the test course.

TEST METHOD NO.2

RIGHT ANGLE TURN

1. Test Course:

(a) Level paved surface

(b) Test course in accordance with "course layout" (see Figure A-1).

2. Test Apparatus:

(a) Tape measure.

(b) Movable vertical barrier.

3. Test Procedure:

(a) Truck is placed on the test course with the most forward edge of centered rated load coincident to line "B". (see Figure A-1). When forks are longer than rated load, the fork tips shall touch line "B" and the fork length is included in the "A" dimension. Mast shall be in the vertical position.

(b) Rated load shall be raised to 6 inches above the surface.

(c) Position movable vertical barrier within 4 inches of counterweight of truck.

(d) Turn steer wheels to the extreme left position and back truck through 90-degree turn.

(e) Measure the perpendicular distance from line "B" to the position assumed by the movable barrier. This is dimension "A".

(f) Return truck to initial position.

(g) Turn steer wheels to extreme right and repeat (a) through (e).

TEST METHOD NO. 3

SPEED

(a) Test course shall be a level paved surface of sufficient length to attain maximum speed prior to entering the measured distance, plus measured distance, plus a safe stopping distance.

2. Test Apparatus:

(a) Tape measure.

(b) Timing device.

3. Test Procedure:

(a) Drive the truck with rated load a sufficient distance to attain maximum speed in high gear prior to entering the measured test course.

(b) Record length of measured distance and time required to traverse measured distance.

Measured distance shall be equal to or greater than 44 feet.

(c) Repeat for a total of six runs, three in forward gear and three in reverse gear, except only time measurement is required.

(d) Travel speeds in forward and reverse gears shall be the average of the three runs.

(f) Repeat operations (a) through (e) without rated load.

TEST METHOD NO.4

SLOPE ASCENSION - PARKING BRAKE

DEADMAN CONTROLS- UNDERCLEARANCE

1. Test Course: Tilt table or ramp.

2. Test Apparatus:

(a) Clinometer.

(b) Spring scale.

3. Test Procedure:

(a) Drive truck forward with rated load along horizontal approach and onto ramp of 22 percent (12.4 degrees) and bring to complete stop (all wheels supported on the ramp).

(b) Apply parking brake, release service brakes and observe whether truck remains stationary.

(c) Reapply service brake, release parking brake and upon removal of operators weight from seat and release of service brakes observe whether truck remains stationary and the deadman control automatically returns the transmission control lever to neutral and activates the indicator light.

(d) Starting from a standstill on the ramp, proceed up and onto a horizontal surface. Stop the truck with the drive wheels on the horizontal surface and the steer wheels on the ramp. Measure and record underclearance beneath the mast assembly, beneath each axle, and the frame of the truck. Record the underclearance of the lowest component and note the component. Note whether any hydraulic components and linkages are not protected.

(e) From a horizontal surface drive truck in reverse down slope, stop on slope and repeat steps

(b) through (d).

(f) Repeat steps 3(a) through 3(e) without rated load.

TEST METHOD NO. 5

COLLAPSED MAST HEIGHT - FREE LIFT HEIGHT -

LIFT HEIGHT – UPRIGHT TILT - SIDESHIFT

1. Test Course:

(a) Level, paved surface.

2. Test Apparatus:

(a) Tape measure.

(b) Plumb bob.

(c) Liquid level or clinometer.

3. Test Procedure:

PART I COLLAPSED MAST (UPRIGHT) HEIGHT

(a) Without rated load and with the forks sitting on the test course measure and record the true vertical distance from floor to uppermost projection of the upright assembly with mast in true vertical position (determined by a clinometer).

PART II FREE LIFT HEIGHT

(a) Raise the rated load until the inner mast begins to exceed the collapsed mast height determined in PART I (a). Stop raising the rated load and measure and record the true vertical distance from the test course to the top surface of the forks.

PART III LIFT HEIGHT

(a) Lower rated load to 12 inches, plus or minus 4 inches, above ground level and position mast in true vertical position using clinometer. Attach a plumb bob to the theoretical intersection of the front surface and top surface of the forks and mark a reference point on the ground.

(b) Elevate the rated load to the maximum lift height and check the reference point. If necessary, reposition the mast so that the plumb bob is directly over the original reference point.

Measure and record the true vertical distance from test course to the top surface of the forks.

PART IV TILT

Test the truck as follows: Place truck without rated load on test course, using clinometer to insure truck is level. Raise forks to an elevation of 2 feet above the surface, tilt mast as far forward as possible, and record angle of tilt shown on clinometer located on front or rear surface of outer mast channel. Next tilt boom as far rearward as possible and record angle of tilt on clinometer located on front surface of outer mast channel.

V SIDESHIFT

Test the truck as follows: Record the sideshift distance from center of carriage and operate the sideshift attachment for 100 full cycles at full speed from extreme left to extreme right and back to extreme left per cycle with the rated load on the forks. During the last 50 cycles, the control shall be released abruptly when the load is in approximately mid position between the left and right extremes. Upon completion of the 100 cycles, the attachment and its components shall be examined for damage. Any evidence of damage shall constitute failure of this test. Test may be interrupted whenever the hydraulic fluid temperature exceeds the maximum operating temperature as specified herein. Test shall resume when fluid temperature reduces to the normal operating temperature.

TEST METHOD NO. 6

LIFT ASSEMBLY DRIFT

(a) Level paved surface.

2. Test Apparatus:

(a) Temperature thermocouples.

(b) Clinometer.

3. Test Procedure:

(a) Install thermocouple in the hydraulic reservoir. Position the truck on the test course and heat the hydraulic oil to 120 degrees minimum by exercising the lift and tilt functions. Maintain hydraulic oil temperature at or above 120 degrees F. temperature during the duration of the test.

(b) Raise rated load to maximum fork height obtainable with outer channel in true vertical position determined with the clinometer. Mark reference points on mast upper stage.

(c) Record initial outer mast position and hydraulic oil temperatures.

(d) Hold for not less than two minutes and record downward drift, rotational drift, and hydraulic temperature.

TEST METHOD NO. 7

OVERLOAD

(a) Level paved surface.

(b) Anchor.

2. Test Apparatus:

(a) Magnetic particle or dye penetrate capability.

(b) Wood blocks.

3. Test Procedure:

(a) Place truck on test course and support truck with blocks under the axle or frame to relieve weight on wheels and tires. Secure truck as necessary with safety cables to prevent truck overturn and to compensate for the test loads to be placed on forks. Position mast in true vertical position. External means may be utilized to hydraulically lock the tilt cylinders. The weighing device and its hydraulic system may isolate during the overload test.

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

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

(d) Check strain on safety cables and inspect the entire truck to determine whether the third test load can be placed on forks. Ascertain if additional safety cables are necessary prior to placement of third test load.

(e) With the crane or another forklift truck, place third test load carefully in position over the first two loads so that the center of mass of load is on the longitudinal centerline of the truck and at the rated load center.

(f) When placing test loads on truck, personnel should stand clear and crane or forklift operator should stand by to remove load if there is any evidence of immediate collapse or truck structure failure.

(g) The 300 percent rated load may be applied as one load in lieu of three loads as described in

(a) through (f). Examination and safety procedures indicated in paragraphs (d) and (f) shall be the same.

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

(i) Remove loads.

(j) Inspect truck structure, frame, mast assembly, the hydraulic system for evidence of deformation, fractures, leakage in hydraulic system, broken welds, etc.

(k) Inspect forks a minimum of 6 inches each side of heel by magnetic particle for steel forks or dye penetrate method for non-ferro magnetic forks.

TEST METHOD NO. 8

INCHING CONTROL

(a) Test course shall be a level paved surface of sufficient length to attain inching speed prior to entering the measured distance, plus measured distance, plus a safe stopping distance.

2. Test Apparatus:

(a) Tape measure.

(b) Timing device

3. Test Procedure:

(a) Place truck on test course with rated load on forks.

(b) Position mast at rearward tilt and raise rated load to 6 inches minimum above the surface.

(c) With direction control in forward position, accelerate the truck to 1/2 mile per hour and at the same time actuate the inching pedal. Record length of measured distance and time to traverse measured distance. Measured distance shall be equal to or greater than 44 feet. Record time in seconds required to raise rated load to maximum lift height during inching.

(d) Repeat for a total of six runs. Test result shall be the average of six runs.

(e) Repeat above procedure in reverse direction.

TEST METHOD NO. 9

TIRE LOADING - DECK LOADING

1. Test Apparatus:

(a) Platform scales.

(b) Plywood panel

2. Test Procedure:

PART I TIRE LOADING

(a) Determine the weight supported by each steer wheel without rated load on the forks by driving the steer wheels onto a platform scale or jacking them up with two axle scales. When the trail wheels are weighed together, the total weight should be divided by the number of steer tires.

The upright shall be in a vertical position, carriage centered and the forks positioned approximately 12 inches above the floor. Determine the steer tire contact area as indicated in

PART II.

(b) Determine the weight supported by the drive wheel(s) with rated load on the forks by driving the left side drive wheel(s) onto a platform scale or utilizing an axle scale. When dual wheels are weighed, divide the total weight by two to determine each tire loading. The upright shall be vertical, carriage positioned at maximum left sideshift position and the forks positioned approximately 12 inches above the floor. Determine the drive tire(s) contact area as indicated in

PART II.

(c) Determine the weight supported by the drive wheel(s) with rated load on the forks by driving the right side drive wheel(s) onto a platform scale or utilizing an axle scale. When dual wheels are weighed, divide the total weight by two to determine each tire loading. The upright shall be vertical, carriage positioned at maximum right sideshift position and the forks positioned approximately 12 inches (305 mm) above the floor. Determine the tire contact area as indicated in PART II.

PART II DECK LOADING

(a) Cover the bottom of the steer and drive tires completely with slow drying paint and lower the wheels onto 1/4 inch plywood panel to establish each tire contact area. When applicable, record each tire pressure.

(b) Calculate and record the actual deck loading for each wheel by dividing the wheel weights determined in PART I TIRE LOADING by the tire contact area determined in step (a).

TEST METHOD NO. 10

RELIABILITY TEST

1. Test Course:

(a) Layout of course. The test course shall be set up equivalent to the provisions of Figure A-2.

Aisle widths shall not exceed the dimensions shown in Table A-I. The course perimeter shall be demarcated with suitable barriers or indicators. Rubber pylons or other suitable marking shall be placed on all corners and other critical points to assist in keeping the truck being tested within the course limits.

Table A-1 Aisle Widths For Test Course

Capacity (lb) Solid Tired Trucks Pneumatic Tired Trucks | 6,000 14 feet 18 feet | | 15,000 -- 25 feet | | 20,000 -- 25 feet |

(b) Obstacle inclusion. The obstacle test shall be set up in accordance with the provisions of Figure A-3 or A-4, as applicable, as a part of the test course. Iron, wood, cement or steel blocks may be used. A guideline 15 feet long shall be provided to the left of the centerline of the course and parallel to it. The inner edge of this guideline shall be at a distance from the course centerline equal to one-half of the truck width or one-half of the load width (whichever is greater) plus 6 inches. This spacing and arrangement will allow the left wheels of the truck under test to pass over the first block and then the right wheels to pass over the second block while the truck is moving forward in a straight line parallel to the guideline.

(c) Ramp inclusion. The course shall include a ramp constructed in accordance with the provisions of Figure A-5.

(d) Course surface. The course shall be paved and shall be clean and free of any unplanned obstacles or foreign material while conducting the reliability test.

(e) Pallet areas.

Position 1: Pallet loads in the first pallet area shall be stacked in accordance with Figure A-6 or A-7, as applicable. They shall be placed 2 inches apart in a direction parallel to, and touching in a direction perpendicular to, the axis of the test course at that point. The stacked marked "X" on Figure A-2 and the limiting (side) stacks shall be high enough that the bottom of the top face of the pallet shall be 6 inches below the maximum lift height of the vehicle under test.

Position 2: Pallet loads in the second pallet area shall be stacked in accordance with Figure A-8 or A-9, as applicable. They shall be placed 2 inches apart in a direction parallel to, and touching in a direction perpendicular to, the axis of the test course at that point. The stack marked "Y" on Figure A-2 and limiting (side) stacks shall be high enough that the bottom of the top face of the pallet shall be at the midpoint between ground level and the maximum lift height of the vehicle under test.

Position 3: Pallet loads in the third pallet area shall be stacked in accordance with Figure A-10.

They shall be placed 2 inches apart, positioned as shown on Figure A-2, in a direction parallel to, and touching in a direction perpendicular to, the axis of the test course at that point. The stack marked "Z" on Figure A-2 and limiting (side) stacks shall be high enough that the bottom of the top face of the pallet shall be at 48 inches height.

2. Test Procedure:

(a) The light switch shall be turned "off" and "on" at the beginning of each lap and upon entering each pallet area.

(b) The truck under test shall begin each lap at the point labeled "STOP & START" on Figure A-2. After the operator starts the truck engine, he shall operate the horn for approximately one second. On lap number 1, the truck shall proceed in a forward direction, following the centerline along the portion of the course marked "A" until it reaches the position 1 pallet area. The rated load will have been previously placed in this location on the stack marked "x".

(c) The truck shall make a 90-degree right-hand turn in one motion without requiring backing operations, proceed to the face of the pallet stack marked "X", raise forks to maximum fork height, then adjust fork height and remove loaded pallet. The truck shall back out of the stack aisle into the main aisle making a 90-degree left-hand turn in one motion, without going forward, and proceed rearward (in reverse) along the main aisle in the portion of the course marked "B" until it reaches position 2 pallet area.

(d) The truck shall proceed rearward (in reverse) to a point beyond position 2 pallet area opening, reverse its direction, and move forward to the face of the pallet stack marked "y", making the 90-degree right-hand turn in one motion without requiring backing operations. The rated load shall be placed on top of the pallet stack marked "Y".

(e) The truck shall back out of the stack aisle into the main aisle, making the 90-degree left-hand turn in one motion without requiring forward operations, and proceed forward along the main aisle in the portion of the course marked "C" until it reaches position 3 pallet area.

(f) The truck shall make a 90-degree right-hand turn in one motion without requiring backing operations and pick up rated load which had been previously placed in the location marked "Z".

The truck shall back out into the main aisle, making the 90-degree right-hand turn in one motion without requiring backing operation, and proceed further along the main aisle in the portion of the course marked "D" until it reaches the portion of the course marked "E", containing the obstacle blocks.

(g) The obstacle blocks shall be traversed by the truck being driven through this area in a straight line so that its left wheels pass over the first block and the right wheels pass over the second block. This part of the test may be conducted at low speed with the transmission in low range. However, the truck shall not be stopped prior to or while going over the blocks.

(h) The truck shall proceed further along the main aisle in the portions of the course marked "F" and "G" until it reaches the position on the ramp labeled "Stopping Point". The driver shall stop the truck, activate the deadman control and then resume ascending the ramp. On the alternate lap the parking brake shall be activated in lieu of deadman control. After the top of the ramp is reached, proceed along the main aisle in the portion of the course marked "J", "K", and "L".

(i) When the truck reaches the portion of the course marked "M", the operator shall stop the truck and operate the sideshift control one time in each direction. On the alternate lap without loaded pallet the operator shall operate the fork positioner (when applicable). After every 25 laps the operator shall stop and restart the engine and test the starter motor safety interlock.

After completion of this portion of the test, proceed along the main aisle and start the next cycle.

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

(k) One-half of the total number of laps shall be traversed in the opposite direction with all operations reversed accordingly. This may be accomplished after completion of each 8-hour operating day or multiple thereof. That is, 50 percent of the laps shall be accomplished in the clockwise direction and 50 percent in the counterclockwise direction or vice versa. The test course need not be rearranged for the reverse travel.

(l) "The Hourly Time Record Sheet" contained herein shall be filled out for each operating hour of the performance test. The number of laps per hour, refueling, reasons for malfunctions, stoppages and safety hazards shall be recorded.

(m) Normal maintenance and inspections shall be performed in accordance with the contractor recommendations furnished prior to commencement of the reliability test.

Custodian: Preparing Activity:

Navy-SA Navy-SA

COURSE LAYOUT

A A

MOVABLE VERTICAL BARRIER

TANGENT POINT

LINE B

FIGURE A-1

MIL-PRF-21868D

33.5 10 (10.2) (3.0)

33.5

(6.1)

(12)

(6.1)

(12)

(16)

(7.6)

(10.2)

(12)

(23)

(7.6)

(19.5)

(19.5)

(7.6)

OBSTACLES

R A

M P

LE

V

E L

R A

M P

START & STOP

POSITION 1

HIGH-LIFT

POSITION 2

MEDIUM LIFT

POSITION 3

LOW-LIFT

STOPPING POINT

WHEN UNDER LOAD

M A

B

C

DEF

G

H

I

J

K

L

Y

Z

(6.1)

(3.7)

FIRE WALL

R

L

F

B

R

L

R

B

F

L

R

L

R

F

F

LF

L

F

F

F

LEGEND:

F = FORWARD

B = BACKWARD

L = LEFT (FACING FORWARD)

R = RIGHT (FACING FORWARD)

A ETC = SECTION DESIGNATION

DIMENSIONS IN FEET (METERS)

1.25

3.75

1.25

(32)

(32)

(95)

1.5 (38)

3.75 (95)

TOP VIEW

FRONT VIEW SIDE VIEW

2 BLOCKS REQUIRED

BLOCKS TO BE ATTACHED TO TEST COURSE AS SHOWN BELOW

DIMENSIONS IN INCHES (MM)

24 (610)

(610)

A _2

A _2

10 FT (3.0 M)

CENTERLINE OF COURSE

AND FORKLIFT TRUCK

DIRECTION OF TRAVEL

A = DISTANCE BETWEEN CENTERLINE

OF DRIVING WHEELS

DIMENSIONS IN INCHES (MM)

UNLESS OTHERWISE NOTED

LAYOUT OF OBSTACLE COURSE

DETAILS OF OBSTACLE CONSTRUCTION

FOR

TRUCK,FORK,LIFT,SOLID RUBBER TIRES

FIGURE A-3

(610)

A _2

A _2

10 FT (3.0 M)

CENTERLINE OF COURSE

AND FORKLIFT TRUCK

DIRECTION OF TRAVEL

A = DISTANCE BETWEEN CENTERLINE

OF DRIVING WHEELS

DIMENSIONS IN INCHES (MM)

UNLESS OTHERWISE NOTED

LAYOUT OF OBSTACLE COURSE

(610)

(610)

TOP VIEW

FRONT VIEW

SIDE VIEW

BLOCKS TO BE POSITIONED ON TEST COURSE AS SHOWN BELOW

DIMENSIONS IN INCHES (MM)

DETAILS OF OBSTACLE CONSTRUCTION

FOR

TRUCK,FORK,LIFT,PNEUMATIC RUBBER TIRES

4 (100)

4 (100)

4 (100)

A

24 (610)

A 6K-10K CAPACITY 3 (76)

15K-20K CAPACITY 4 (100)

FIGURE A-4

12 (300)

(100)

(100)

R A

M P

T O

B E

IN

C H

(1

M M

) P A

D (C

O N

C R

E

TE

O R

E Q

U

IV

AL

E

N T)

, F

IN

E

FL

O

AT

F

IN

IS

H

O N

C O

M

PA

C T

FI

LL

C

U R

B

IN

G T

O B

E R

E

IN

FO

R

C

ED

(1

2.

2)

(1

2.

2)

2 0 ( 6

. 1

(1

.2

6" (1

M

M )6"

(1

M M

(3

.7

D

IM

E N

S

IO

N S

IN

F

E E T

( M ) U

N

LE

SS

O

TH

ER

W

IS

E N

O

TE

D

R A

M P

D

ES

IG

N

FI

G

U R

E A-

PALLET

GROUND

LINE

STANDARD

TEST LOAD

48 48 (1220) (1220)

B

(3660)

FRONT FACE OF LIMITING STACKS

ARE ON EDGE OF THE TEST COURSE

A

TOP VIEW

FRONT VIEW SIDE VIEW

A = MAXIMUM LIFT HEIGHT FOR FORKS

LESS 6 INCHES (150 MM)

B = WIDTH OF TRUCK + 12 INCHES (300 MM)

SUPPORT FOR STANDARD LOAD SHOULD BE

OF SUITABLE STRENGTH TO SUSTAIN TEST

LOAD. LIMITING STACKS MAY BE PALLETS,

PALLET RACKS OR BOTH.

FIGURE A-6

DIMENSIONS IN INCHES (MM)

STACK LAYOUT - POSITION 1

SOLID RUBBER TIRED TRUCKS

PALLET

GROUND

LINE

STANDARD

TEST LOAD

A

FRONT VIEW SIDE VIEW

48 48 (1220) (1220)

B FRONT FACE OF LIMITING STACKS

ARE ON EDGE OF THE TEST COURSE

TOP VIEW

A = MAXIMUM LIFT HEIGHT OF FORKS LESS 6 INCHES (150 MM)

B = WIDTH OF TRUCK + 12 INCHES (300 MM)

SUPPORT FOR STANDARD LOAD SHOULD BE OF SUITABLE STRENGTH

TO SUSTAIN TEST LOAD. LIMITING STACKS MAY BE PALLETS, PALLET

RACKS, OR BOTH.

DIMENSIONS IN INCHES (MM)

FIGURE A-7

STACK LAYOUT - POSITION 1

PNEUMATIC RUBBER TIRED TRUCKS

LIMITING STACKS

48 48 (1220) (1220)

B

(3660)

TOP VIEW

PALLET

STANDARD

TEST LOAD

GROUND

LINE

FRONT VIEW SIDE VIEW

FRONT FACE OF LIMITING STACKS

ARE ON EDGE OF THE TEST COURSE

STACK LAYOUT - POSITION 2

SOLID RUBBER TIRED TRUCKS

A = ONE-HALF MAXIMUM LIFT HEIGHT OF FORKS

B = WIDTH OF TRUCK + 12 INCHES (300 MM)

SUPPORT FOR STANDARD LOAD SHOULD BE OF SUITABLE STRENGTH

TO SUSTAIN TEST LOAD. LIMITING STACKS MAY BE PALLETS, PALLET

RACKS, OR BOTH.

DIMENSIONS IN INCHES (MM)

A

FIGURE A-8

B FRONT FACE OF LIMITING STACKS

ARE ON EDGE OF THE TEST COURSE

TOP VIEW

LIMITING STACKS

PALLET

GROUND

LINE

STANDARD

TEST LOAD

A

FRONT VIEW SIDE VIEW

B = WIDTH OF TRUCK + 12 INCHES (300 MM)

SUPPORT FOR STANDARD LOAD SHOULD BE OF SUITABLE STRENGTH

TO SUSTAIN TEST LOAD. LIMITING STACKS MAY BE PALLETS,

PALLET RACKS, OR BOTH.

DIMENSIONS IN INCHES (MM)

A = ONE-HALF MAXIMUM LIFT HEIGHT OF FORKS

(2440)

STACK LAYOUT - POSITION 2

PNEUMATIC RUBBER TIRED TRUCKS

FIGURE A-9

B = WIDTH OF TRUCK + 12 INCHES (300 MM)

A FRONT FACE OF LIMITING STACKS

ARE ON EDGE OF THE TEST COURSE

TOP VIEW

(2440)

GROUND

LINEFRONT VIEW SIDE VIEW

PALLET STANDARD

TEST LOAD

A = WIDTH OF TRUCK + 12 INCHES (300 MM)

DIMENSIONS IN INCHES (MM)

LIMITING STACKS MAY BE STACKED PALLETS

STACK LAYOUT - POSITION 3

FIGURE A-10

HOURLY TIME RECORD SHEET

TRUCK MANUFACTURER

MODEL

SERIAL NO.

DATE

CLOCK READINGS:

START

FINISH

TEST LOCATION

RECORDED BY

TIME LAPS AVG LAP TIME COMMENTS

INSTRUCTIONS:

1. START DECIMAL MINUTE STOP WATCH AT ZERO AT BEGINNING OF EACH HOUR.

2. RECORD WATCH READING AT END OF EACH HOUR AND RECORD ELAPSED TIME.

FIGURE A-11