NAVSUP_WSS_PD-515_-_dtd_03_NOV_2016.pdf

NAVSUP WSS PD-515

03 November 2016

Supersedes

23 August 2016

PURCHASE DESCRIPTION

CRANE, MOBILE, DIESEL ENGINE, 15 TON CAPACITY,

PNEUMATIC RUBBER TIRES, MARINIZED

1. SCOPE

1.1. This purchase description (PD) covers the requirements for a commercial crane for shipboard use.

The crane covered in this specification has a 15 US ton capacity lifting capability, and is diesel powered with pneumatic tires.

1.2. Intended Use. Mobile cranes are used afloat and are intended to hoist or lower general supplies.

Additionally, the mobile crane will be used for handling ordnance afloat.

2. APPLICABLE DOCUMENTS

2.1. Government documents.

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

SPECIFICATIONS

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

Requirements for MIL-PRF-2104 - Lubricating Oil, Internal-Combustion Engine, Combat Tactical Service.

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades, JP-4, and JP-5 MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type JP-8 (NATO F-34), NATO F-

35, and JP-8+100 (NATO F-37) MIL-DTL-16884 - Fuel, Naval Distillate MIL-PRF-17672 - Hydraulic Fluid, Petroleum, Inhibited.

MILITARY SPECIFICATION SHEET

A-A-52464 - Lunette Coupler, Drawbar Ring

A-A-52550 – Pintle Assembly

Beneficial comments (recommendations, additions, and deletions) and any other pertinent data which may be of use in improving this document should be addressed to: Department of the Navy, NAVSUP Weapons System Support, Code N954 5450 Carlisle Pike ‐ P.O. Box 2020 Mechanicsburg, PA17055‐0788.

AMSC N/A FSC 3810

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

STANDARDS

FEDERAL

FED-STD-595 - Color NAVFAC P-307 - Management of Weight Handling Equipment NSTM Chapter 589 - Naval Ships’ Technical Manual - Cranes RR-W-410G - Wire Rope and Strand NAVICP-PD-21861 – Manual, Technical, Materials Handling Equipment DODD 4100.39 - FLIS Procedures Manual General and Administrative Information

MILITARY

MIL-STD-130 - Identification Marking of U.S. Military Property MIL-STD-209 - Lifting and Tiedown Provisions MIL-STD-461 - Requirements for the Control of Electromagnetic Interference Emissions and

Susceptibility MIL_STD-464 - Electromagnetic Environment Effects Requirements for Systems MIL-STD-810 - Environmental Test Methods and Engineering Guidelines.

MIL-STD-889 - Dissimilar Metals.

MIL-STD-3034A - Reliability-Centered Maintenance (RCM) Process MIL-STD-1472 – Human Engineering MIL-STD-1474 - Department of Defense Design Criteria Standard, Noise Limits

MIL-STD-31000 – Technical Data Packages

MILITARY HANDBOOK

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

2.1.2. Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this specification to the extent specified herein.

ENVIRONMENTAL PROTECTION AGENCY (EPA)

Protection of Environment.

Title 40 Code of Federal Regulations.

DEPARTMENT OF LABOR

Occupational Safety and Health Administration (OSHA), Standard 29 CFR 1910 Occupational Safety and Health Administration (OSHA), Standard 29 CFR 1926 (Application for copies should be addressed to the Superintendent of Documents, Government Printing Office, Washington, D.C. 20402.)

2.2. Other publications. The following document(s) form a part of this specification to the extent specified herein. The issues of the documents which are indicated as DoD adopted shall be the issue listed in the issue of the DoDISS specified in the solicitation.

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

Z26.1 Safety Glazing Materials for Glazing Motor Vehicles Operating on Land Highways.

(Application for copies should be addressed to the American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

D - 1171 Rubber Deterioration - Surface Ozone Cracking Outdoors or Chamber.

D - 3951 Standard Practice for Commercial Packaging.

D - 1655 Standard Specification for Aviation Turbine Fuels (Application for copies should be addressed to the American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE Handbook.

SAE J88 – Machines, Off-Road Work-Exterior, Sound Measurement SAE J159 - Load Moment System SAE J375 - Radius-of-Load or Boom Angle Indicating Systems SAE J376 - Load Indicating Devices in Lifting Crane Service SAE J386 - Machines, Operator Restraint System for Off-road Work SAE J517 - Hydraulic Hose SAE J553 - Circuit Breakers SAE J695 - Motor Vehicles - Turning Ability and Off Tracking SAE J765 - Crane Load Stability Test Code SAE J994 - Alarm-Backup-Electric-Laboratory Performance Testing SAE J1063 - Crane Structures, Cantilevered Boom, Method of Test SAE J1171 - External Ignition Protection of Marine Electrical Devices SAE J1180 – System, Telescopic Boom Length Indicating (Application for copies should be addressed to the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B30.5 Mobile and Locomotive Cranes.

Boiler and Pressure Vessel Code, Welding Qualifications, Section IX.

(Application for copies should be addressed to the American Society of Mechanical Engineers, 345 East 47th Street, New York, NY 10017.)

AMERICAN WELDING SOCIETY, INC. (AWS)

D1.1 - Structural Welding Code, Sections 5 and 6, Welding Qualifications.

D14.3 - Earthmoving and Construction Equipment Welding, Section 5, Qualification.

(Application for copies should be addressed to the American Welding Society, Inc., 2501 N.W. Seventh Street, Miami, FL 33125.)

TIRE AND RIM ASSOCIATION, INC. (TRA)

Tire and Rim Association Yearbook.

(Application for copies should be addressed to the Tire and Rim Association, Inc., 3200 West Market Street, Akron, OH 44313.)

POWER CRANE AND SHOVEL ASSOCIATION (PCSA)

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

2.3. Order of precedence. In the event of a conflict between the text of this specification and the references cited in 2.1.1, 2.1.2, and 2.2, the text of this specification shall take precedence.

3. REQUIREMENTS

3.1. Design. The crane shall be designed for the lifting capacity (rated load) as specified. It shall be four wheel drive (if commercially available), pneumatic tired, and have options for two-wheel, four-wheel, and crab steer with electronic self-alignment. The crane shall be diesel powered, and have a full revolving hydraulic telescoping boom. The crane shall conform to the requirements of ASME B30.5.

Additionally the crane shall conform with OSHA, SAE, NSTM 589 and NAVFAC standards as applicable. An operator’s seatbelt conforming to SAE J 386, and restraint devices designed to ensure the operator's upper body remains entirely within the protection of the overhead guard in the event of tipover shall be provided.

3.2. Physical characteristics.

3.2.1. Weight. With the crane fully fueled and serviced, the maximum allowable vehicle weight shall be 30,000 pounds.

3.2.2. Overall height. The overall crane height, with the boom horizontal shall not be more than 8 feet 2 inches.

3.2.3. Overall retracted length. The overall crane length, with the boom retracted shall not be more than 23 feet.

3.2.4. Overall collapsed width. The overall crane width, with outriggers retracted, shall not be more than 8 feet.

3.2.5. Ground clearance. Minimum ground clearance shall not be less than 10 inches when the crane is fully fueled and serviced. Removal of the outrigger floats to obtain these heights is permitted.

3.3. Transportability. The crane shall be transportable without sustaining damage by highway, marine, and rail modes of transportation.

3.4. Crane structure. The structure of the crane shall be such that stresses induced during required operations do not exceed the allowable strength margins of SAE J1063.

3.5. Materials. Materials shall be as specified herein. Materials not specified shall be selected by the contractor and shall be subject to all provisions of this specification. Unless otherwise specified herein, all equipment, material, and articles incorporated in the work covered by this specification are to be new.

3.5.1. Recovered materials. The components, pieces and parts incorporated in the cranes may be newly fabricated from recovered materials to the maximum extent practicable, provided the cranes produced meet all other requirements of this specification. Used, rebuilt or remanufactured components, pieces and parts shall not be incorporated in the crane.

3.5.2. Dissimilar metals. Unless suitably protected against galvanic corrosion, dissimilar metals shall not be in intimate contact with each other unless suitably protected against electrolytic corrosion. Dissimilar metals and methods of protecting them are defined and described in MIL-STD-889.

3.5.3. Drain holes. Structures shall be designed to eliminate pockets where debris and water might accumulate. All structural configurations shall allow water run-off, or shall have adequate sized and placed drain holes.

3.6. Environmental and use requirements.

3.6.1. Operating conditions. The crane shall withstand the usage encountered in military operations without damage, permanent deformation or failure of components. The primary military operations are loading and unloading of general palletized goods and ordnance during shipboard operations, pierside and underway/at sea.

3.6.2. Operating temperature. The crane shall be capable of operating in temperatures ranging from -10° F to +120° F. The power source shall start within 5 minutes.

3.6.3. Rain. The crane shall be capable of starting within 5 minutes and operating as specified herein after experiencing rainfall conditions of 4 inches per hour with 40 mile-per-hour winds for no less than 30 minutes.

3.6.4. Wind. The crane shall be capable of operating in wind speeds up to 30mph (26 knots). The crane shall be outfitted with a wind speed indicator, with a digital readout in the operator’s cab.

3.7. Safety. The crane shall meet the safety requirements specified in OSHA 29CFR 1926, PCSA 4, ASME B30.5 and other applicable OSHA standards in effect at the time of issue of the solicitation, unless otherwise specified herein. All rotating and reciprocating parts and parts subject to high temperature shall be guarded when such parts are exposed to contact by operator and maintenance personnel performing daily maintenance functions. Nonfunctional edges shall be rounded, projecting points shall be blunted or rounded, and excessive length of fasteners shall be avoided. Steps and platforms for entering the crane shall have antiskid, ice resistant surfaces. Oil level indicators for engine, transmission, and other components shall be within easy and safe access of the operator or maintenance personnel. Portions of the superstructure that extend out and over the carrier, when being swung where it may cause a striking or crushing hazard for personnel, shall have the lower and back area taped in black and white striping.

3.7.1. Backup alarm. A backup alarm conforming to SAE J994, type C or D shall be furnished. The backup alarm signal shall be audible above, and distinguishable from the surrounding vehicle noise level.

3.7.2. Load rating chart. On land load rating chart in accordance with ASME B30.5 shall be provided and shall contain not less than the following information:

- Rated loads in pounds in not more than five-foot increments for the full range of operating radii with and without outriggers.

- Rated loads shall not exceed 85 percent of the tipping loads on outriggers or 75 percent of the tipping loads on rubber.

- Definition of the load to be lifted.

- Hook block reeving.

A separate, down-rated table shall be provided for crane operation on outriggers, Shipboard. This table may be included as a part of the primary load chart, or provided as a separate chart. The parameters and load factors for shipboard operation are defined in section 3.11.6.

3.8. Human factors. The characteristics of the fully assembled crane shall provide for operation and maintenance by personnel ranging from the 5th percentile female, through the 95th percentile male, clothed, in accordance with MIL-STD-1472. Components and equipment removed, disassembled or relocated for operation maintenance, or transportability as specified in section 3.3, which must be lifted or carried by operating personnel, shall not exceed 50 pounds in weight for one person lifts and 100 pounds for two or more person lifts, and shall be provided with suitable handles or grasp areas. Human factors specifications from MIL-STD-1472, as applicable, shall be incorporated in the crane.

3.8.1. Seatbelt. An adjustable weather-resistant seatbelt with buckle conforming to SAE J386, type I shall be furnished equipped with sleeves and retractor or seat mounted.

3.8.2. Noise limits.

3.8.2.1. Personnel limits. The sound level at the operator's station shall not be equal to or greater than 85 dBA.

3.8.2.2. Exterior noise. The noise level of the crane (excluding horn and back-up alarm) shall not be equal to or greater than 85 dBA when tested in accordance with SAE J88.

3.9. Maintainability. Provision shall be made for adjustment, servicing or replacement of parts and components. When access openings are used on the exterior of the crane, the edge of the opening shall be smooth and shall be provided with a removable or hinged cover whenever it is required. When tested as specified (4.4.1.16), the crane shall have a maintenance ratio (MR) of not more than 0.25. The MR is defined as the ratio of total active maintenance man-hours required (scheduled and unscheduled) to the total operating time. Man-hours for repair of replaced components and scheduled before-and-after operation checks are excluded. Scheduled maintenance shall be required not more often than every 50 hours, except for before-and-after operation checks. Each operation in the following maintenance operations list shall be accomplished by one person (except where otherwise specified) in not more than the time specified, using common tools and special tools, if any, furnished with the crane.

a. Remove, replace and adjust all engine-driven belts - 3/4 hour. (excluding engine-timing belt)

b. Remove and replace alternator - 1hour.

c. Remove and replace all hydraulic-system filters - 1 hour.

d. Remove and replace engine coolant-system hoses - 1 hour.

e. Drain engine lubricating oil, remove and replace oil filter elements and refill crankcase – 1.5hour.

f. Remove and replace fuel filter elements - 1/2 hour.

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

h. Drain torque converter oil and transmission oil, remove and replace all transmission filter elements and strainers, and refill-converter and transmission - 2 hour

i. Remove and replace starter – 1 hour.

j. Bleed and adjust brakes and refill master cylinder - 2 men, 1 hour.

k. Remove and replace headlight, floodlight and taillight bulbs - 1/4 hour each bulb.

l. Remove, disassemble, service and install air cleaner - ½ hour.

m. Lubricate all lubrication fittings with 2 strokes per fitting using the gun and extension, if needed - 1 hour.

3.10. Reliability. The crane(s) shall be capable of completing 1200 circuits of the test course specified herein (4.4.1.30).

3.11. Performance. The crane shall conform to the requirements specified herein under all conditions specified without damage or permanent deformation. There shall be no evidence of accelerated wear or failures when operated under all specified service conditions.

3.11.1. Stability.

3.11.1.1. ANSI stability. The crane and On-Land Load Charts shall conform to ASME B30.5 and SAE J765 stability requirements.

3.11.1.2. Gradeability/Ramp Stability. The crane while descending or ascending a 30 percent grade (17 degrees) without load in the forward or reverse direction, at not less than 2 mph, shall be capable of stopping within a distance of 20 feet by applying the service brakes at a pressure that prevents the rear wheels from leaving the ground. The crane, when stopped on a 30 percent slope, shall be held by the service brakes for not less than 1 minute.

3.11.2. Longitudinal gradeability. The crane shall ascend a 30 percent grade (17 degrees) in forward gear range at a speed of approximately 2 mph without a load. Front wheel drive vehicles may ascend the ramp in reverse to meet the requirement.

3.11.3. Lifting speeds.

3.11.3.1. Boom lift speed. The boom lift (elevation) speed shall not be less than 1.5 degrees per second.

3.11.3.2. Hook lift speed. The main hook block lifting speed with the recommended number part lines shall not be less than 100 feet per minute.

3.11.4. Outside turning radius. The minimum outside turning radius in two-wheel steer shall be no greater than 22 feet. The minimum outside turning radius in four-wheel steer shall be no greater than 16 feet. The turning radius shall be measured to the outermost corner of the crane’s chassis and shall not take into account the turning radius of the boom.

3.11.5. Crane Capacity On Land. The crane on fully extended outriggers shall be capable of engaging and lifting, swinging 360 degrees, and disengaging the following loads excluding the weight of the main block at the specified heights and radii:

Load Radius Hook Height 6,000 lb. 24 feet 36 feet 12,000 lb. 16 feet 40 feet

18,000 lb. 10 feet 30 feet 30,000 lb 6 feet 20 feet

3.11.6 Crane Capacity Shipboard. The crane manufacturer shall analyze and provide a separate load chart for shipboard operation on fully extended and deployed outriggers on the ship using the following accelerations. Assume that the loads are acting on the crane simultaneously:

a. Maximum Roll Force Estimate – 0.130g

b. Maximum Heave Acceleration – 1.0g +/- 0.113g Roll force estimate acts parallel to the deck at all times, and incorporates the maximum roll angle of the ship. Heave acceleration is an upward or downward acceleration with respect to gravity (a value of 1.0g is normal acceleration due to gravity). With the load factors listed, the crane must have the following minimum capacities, including the weight of the main block:

Load Radius 3,000 lb 26 feet (10’ minimum clear outreach from crane) 7,500 lb 16 feet (5’ minimum clear outreach from crane)

3.11.7. Drift. The boom lift assembly, with hydraulic fluid at normal operating temperature, shall be capable of holding the rated load at maximum lift height with full boom extension for not less than 10 minutes with not more than 1.0 inch of cylinder travel and not more than 0.5 degree of rotational drift.

This test shall be performed with the boom and test load extended out over each outrigger. A total of 4 tests shall be performed measuring the boom assembly and each outrigger for drift. (see Test Method No. 5)

3.12. Superstructure. The revolving superstructure assembly shall be capable of continuous 360-degree operation. The superstructure shall be capable of a swing speed of not less than 1.75 rpm and not more than 3.5 rpm at governed engine speed with the swing control on the full open position and shall be equipped with a swing brake and lock. The counterweight shall be made of a homogeneous material.

3.12.1. Pedestal. The pedestal and base shall be mounted on the chassis to insure continuous 360-degree working range and shall withstand the forces caused by lifting, swinging with rated loads, and traveling without loads.

3.12.2. Boom assembly. The boom shall be of steel construction and of the full power telescopic type having 3 sections consisting of a base section and 2 hydraulic / mechanical powered telescopic sections.

The extended boom length shall not be less than 32 ft. The boom extension system shall be of a positive mechanical / hydraulic type to ensure equal extension of the telescopic sections at any boom length. All telescopic sections shall be adequately supported on friction type wear pads to prevent metal- to-metal contact between the sliding sections. Telescoping of the boom shall be accomplished by a single hand operated lever. The boom head shall be designed to permit reeving changes without becket and wedge removal. If the boom head, block, and hook measures greater than 60” in its maximum stowed configuration (excluding the length of the insulating link), a pivoting head design shall be incorporated, utilizing multiple pinning positions which minimize the required boom headroom to operate to less than 60”. A jib boom extension shall not be provided unless explicitly requested by the purchaser.

3.12.3. Hook Block and Hook & Ball. The crane shall be provided with a suitable sheave block to permit lifting maximum capacity as well as a hook & ball for single part line operation. Both configurations shall have a forged carbon steel hook produced against special Navy NDT from hook OEM, in accordance with NAVFAC P-307, appendix E, section 1.4.4. Both hook block and hook & ball shall be of the design so as to eliminate the need to remove the becket & wedge from the end of the wire rope when changing reeving. Sheave block shall incorporate metallic sheave (s) and an anti-friction type 360˚ swivel and pivoting hook. Hook & ball shall also include a 360˚ swivel. Both shall be of a low profile design with safety latches on the hooks. The crane shall be delivered with the sheave block installed and the hook & ball packaged and secured for shipment in the operators compartment.

3.12.4. Hoist. The crane shall be provided with a hydraulically driven hoist drum. The assemblies shall include a self-locking mechanism or self-energizing brake capable of holding their respective maximum rated loads. An anti-two block feature shall be provided and tested as specified (4.4.1.20). The crane shall be equipped with provisions for emergency lowering of a load in the event of hydraulic or electrical failure, and tested as specified (4.4.1.6).

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

3.12.4.2 Hoist drum rotation indicator. If the hoist drum is not visible from the operator’s cab, a drum rotation indicator shall be provided, in accordance with OSHA 29CFR 1926 and ASME B30.5. The rotation indicator display shall be located in the cab, to permit sensing by the operator.

3.12.5. Wire rope. The crane shall be provided with a minimum of 240 feet of rope length. In accordance with PCSA 4, a lower limit stop shall be implemented that ensures at least 2.5 dead wraps remain on the drum. The wire ropes shall be in accordance with RR-W-410G and shall have safety factors not less than recommended by ASME B30.5.

3.12.6. Boom angle and boom length indicators. A boom angle indicator shall be provided which shows angular elevation of the boom and conforms to SAE J375. The boom angle indicator shall be visible to the operator in his normal seated position. A boom length indicator shall also be provided in increments to match with the load capacity chart in accordance with SAE J1180.

3.12.7. Load indicating and warning device. A load indicating and warning device of the load-moment type shall be provided to perform the following functions while on outriggers and be tested as specified in 4.4.1.18:

a. Provide a dial or digital reading of hook load in pounds.

b. Provide a dial or digital reading of boom length in feet.

c. Provide a dial or digital reading of load moment as a percentage of rated capacity.

d. Provide visual warning (amber light) when load-moment reaches 85 percent of rated capacity, visual and audible (red light and alarm) warning at a 95 percent rated capacity, and control lock out for boom lowering and extension at 100 percent rated capacity.

e. The device shall provide for manual selection of parts of line. The device shall be hard wired. The device shall conform to SAE J159, J375, and J376.

f. The load indicating device shall be programmable to toggle between capacities for both On Land and Shipboard operation.

3.12.8. Lift and extension mechanism. The crane shall be capable of accomplishing hoist and boom extension both simultaneously and independently. Control valves or other positive means shall be provided to prevent cavitation in the lifting/lowering cylinders and the extension/retraction cylinder(s).

3.13. Outriggers. Four independently hydraulically operated outriggers, capable of extension to not less than 2 inches below ground level, shall be provided. The outriggers shall be operated from the operator's compartment and shall not collapse due to loss of hydraulic pressure in the supply lines. The outrigger floats shall be designed and installed to evenly displace the load over their entire contact surface. Float size and loading shall comply with deck loads as stated in 3.38. An indicator shall be provided for the operator to determine levelness of the crane during operation of the outriggers. An audible alarm shall be provided that activates when outriggers are being raised/lowered. Means shall be provided to prevent the operator from accidentally retracting the outriggers.

3.14. Lubricants. Cranes 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 are permitted for shipboard cranes.

3.15. Diesel engine (Tier III Rated). The engine, including all systems, components, and accessories, shall conform to current US Environmental Requirements and shall be Tier III rated. A sleeveless engine is acceptable. The engine shall be capable of operating on the following fuels: JP-5 (F-44) conforming to MIL-DTL-5624 and JP-8 (F-34) conforming to MIL-DTL-83133. Performance testing shall be conducted using these aviation turbine fuel. If problems acquiring JP-5 or JP-8 for testing are experienced, Jet A or Jet A-1, per ASTM D1655, be may substituted. All performance tests shall be conducted using the same/one types of fuel. All engine accessories shall be furnished by or approved by the engine manufacturer for this application. The engine shall be capable of operating on lubricating oils as specified in MIL-DTL-16884. The Navy shall be responsible for providing any required EPA waivers associated with using a Tier III, vice Interim Tier IV or Tier IV engines. Manufacturer shall be responsible for submitting these waivers and subsequent procurement of the Tier III engine. Unless otherwise specified herein, the engine shall meet all operational requirements and conditions of the engine manufacturer's recommended operating limits when operating in a -10 °F to 120 °F ambient environment. Emergency manual shutdown provisions shall be furnished when recommended by the engine manufacturer.

3.15.1. Power and speed rating. The power and speed rating of the engine shall be such that operation of the crane under any of the operational requirements and conditions specified herein will not require horsepower in excess of the intermittent horsepower rating of the engine for the applicable governed speed as established by the engine manufacturer.

3.15.2. Alternator (Enclosed). The alternator shall have output capacity sufficient to meet the electrical load required by the engine and to support the complete crane 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. Alternator shall be enclosed, conforming to SAE J1171, or approved equal.

3.16. Engine sub-systems.

3.16.1. Fuel system. The crane shall have all necessary filters, water separators, and components required for operation. The crane shall have a fuel tank of sufficient capacity to allow at least 3.5 hours of continuous operation (4.4.1.30). Fuel tank shall not be located over the engine. If tank and engine are in the same compartment, it shall be isolated from electrical and exhaust systems by an enclosure. A manual shutoff shall be provided near the tank on systems where fuel is subject to discharge if a fuel line breaks.

Fuel tank location and chassis design should prevent fuel from spilling from the vehicle, to the greatest extent practical, before the leak can be isolated.

3.16.2. Starting system. The starter switch shall not activate the engine starter while the engine is running, nor when the engine is not running and the transmission is in any forward or reverse gear. The starter switch shall only operate when the transmission is in the “neutral” or “park” positions.

3.16.3. Exhaust system. The engine exhaust system shall be protected against entry of rain. Exhaust gases shall be discharged vertically above the operator's head or at the rear or side rear of the crane within the plane outline of the crane. The exhaust system shall be designed to prevent burns to the operator and maintenance personnel while working or operating the crane. An SAE approved spark arresting muffler shall also be provided that is sufficiently rated to the size of the engine.

3.16.4. Electrical system. The crane shall have a 12-volt electrical system. Starting battery shall be Absorbed Glass Mat (AGM) type. Grommets shall be provided whenever wiring passes thru bulkheads, partitions, structural members and the wiring shall be fastened to prevent chafing or abrasion. All wiring shall be color-coded and/or numbered in accordance with the wiring diagram in the technical manual. Each electrical circuit shall be protected from electrical overload with circuit breakers in accordance with SAE J553. Fuses are not permitted.

3.16.5. Hand Priming Pump. A hand priming pump shall be provided to assure delivery of fuel to the injector pump after fuel supply has been exhausted.

3.16.6. Manual Disconnect Switch. A manual electrical disconnect switch shall be readily accessible to the operator in their normal operating position.

3.17. Transmission. Either a hydrostatic or a torque converter/powershift type of transmission shall be furnished. Powershift transmission shall incorporate at least four forward gears and four reverse gears.

Transmission direction/gear selection control shall accurately identify selected position with any excess or unused positions on the control disabled to prevent selection and related position markings removed.

3.18. Hydraulic system. A pressure relief protection device is required along with pump(s), cylinders, control valves, filter(s), reservoir, hoses, and all other components necessary to make a complete hydraulic system. In the event of hydraulic system damage or failure, a means to prevent the boom from automatically lowering/retracting/tilting shall be provided. The hydraulic system shall prevent the load from falling more than 0.5 inches after system failure. A manual override system shall be provided to allow for safe load removal. Instructions shall be provided to the operator on emergency lowering procedures in the event of system failure.

3.18.1. Relief valve. A hydraulic-system relief valve shall be provided to protect the hydraulic system from pressures in excess of that specified herein.

3.18.2. Cylinders. All hydraulic system and steering cylinders shall be fabricated from either seamless steel tubing, or welded and redrawn tubing. Hydraulic cylinder piston rods shall be provided with a hard chrome plate finish capable of resisting the effects of corrosion as a result of the environmental requirements specified herein (3.42). Plating shall be electro-deposited hard chromium finish, having uniform thickness of not less than 0.001 of an inch. Nitrosteel (salt bath ferritic nitrocarburizing SBN) in lieu of chrome plating on the hydraulic cylinders is acceptable.

3.18.3. Hoses. 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 the place of the original hose assembly. Thermoplastic hoses in accordance with SAE J517: 100R7 or 100R8 are not permitted.

3.19. Steering. The steering method shall provide the operator with a choice of two wheel, four wheel, and crab steer capabilities. An indicating light shall be provided on the instrument panel to indicate when the rear wheels are positioned other than straight ahead. The steering system shall be controlled by a single steering wheel. Emergency steering shall be provided for retaining steering control in the event of engine failure or steering power source failure when traveling at any speed to the maximum speed of 14 mph.

3.20. Brakes. Service and parking brakes shall be provided and shall be independently actuated systems.

3.20.1. Service brakes. The service braking system shall be a commercially available system provided by the manufacturer. The service brakes shall be capable of bringing the crane to a complete safe stop in accordance ASME B30.5. Not more than 80 pounds of force on the brake pedal shall be required to meet the requirements of ASME B30.5.

3.20.2. Parking brake. When the crane, without a load, is stopped on a 30 percent (17 degree) grade in both the ascending and descending position, the parking brake(s) shall hold the crane stationary. The parking brakes shall be located within reach of the seated operator. The brake shall have a locking device. The force required to pull the hand lever when setting the brake shall not exceed 35 pounds. The parking brake shall be independent from the service brakes.

3.20.3. Deadman Control. The crane shall be provided with a deadman control, such that upon removal of the operator’s weight from the seat, the deadman control shall stop the vehicle by appling braking force to the drive wheels and 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 red or amber 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. Instruments and controls. Crane 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) and fuel gauge. Gauges, indicator lights and meters shall be constructed to be corrosion and weather resistant. Gauges shall be internally lighted. Whenever indicator light instruments are furnished, means shall be provided to check operation of the light

3.22. Lighting. A minimum of (2) headlights, (1) boom-mounted light, a variable light to illuminate the working area, and 4-way hazard warning lights shall be furnished. Tail light(s) and brake stop light(s) shall be installed. Individual operator controlled switches shall be provided. Each headlight and the boom light shall be furnished with three sets of lenses. Color of lenses shall be blue, red and yellow.

Red and yellow lenses shall be stored in a pocket located on the back of the operator's seat.

3.23. Horn. An electric horn shall be provided with the capability to exceed a level of 88 dB (A).

3.24. Body, cab, cowls.

3.24.1. Cab. The crane shall be equipped with an enclosed cab and shall have a door with at least one window, which can be opened for ventilation. The door shall be provided with hinges that can be serviced without door removal. In addition to the door window, the cab shall be furnished with a front windshield, rear window, and side windows. The windshield and all windows shall be laminated safety glass. Dual rear view mirrors shall be provided. The cab interior shall be furnished with water-resistant non- absorbent thermal insulation. A commercial fire extinguisher shall be mounted on the crane in an easily accessible location. The fire extinguisher shall be a minimum 2-1/2 pound capacity ABC type, or equivalent. The fire extinguisher shall be UL listed.

3.24.2. Body. The crane body cowl or hood and access covers shall be constructed of commercially accepted materials.

3.24.3. Cowl or hood. The engine shall be completely enclosed with a hood cover and side plates. Hood cover, if lift-up type, shall be held in the open position in a safe manner with gas operated cylinders or spring and linkage mechanism or latch, which requires no brace, or support and cannot be inadvertently released while servicing the vehicle. Hand tools shall not be required for release of hood or side plates.

All engine components (accessories) shall be accessible, without requiring the removal of any additional crane structure, when hood cover and side plates are opened.

3.25. Windshield wipers. There shall be at least one wiper on the front window.

3.26. Winterization. At a minimum, the following items shall be provided.

3.26.1. Engine coolant heater. An engine coolant heater shall be installed in the engine block or lower coolant inlet hose. A coolant-circulating pump, driven by a 110 volt or 220 volt alternating current motor, shall be provided when a coolant inlet hose heater is furnished. The heater shall have adequate capacity to maintain engine coolant at a temperature of +10° F in an ambient temperature of -10° F. It shall be controlled to limit engine coolant to not more than 150° F.

3.26.2. Engine oil heater. An engine oil heater with adequate capacity to maintain engine oil at a temperature of at least +10 degrees F in an ambient temperature of -10° F shall be furnished. It shall be controlled to limit engine oil temperature to not more than 150 ° F.

3.26.3. Battery heater. A battery heater shall be provided. It shall have adequate capacity to maintain battery electrolyte at a temperature of at least +10° F in an ambient temperature of -10°F, and shall have a thermostat to limit temperature of the electrolyte to not more than +80°F.

3.26.4. Heater and defroster. The heater shall be of sufficient capacity to maintain a temperature of +40° F at cab floor level in an ambient temperature of -10° F.

3.26.5. Cold starting aid. Diesel engine driven cranes shall be equipped with glow plugs.

3.26.6. Antifreeze. Engine coolant shall be protected to -10° F.

3.27. Travel speed. The crane without load shall be capable of attaining and maintaining a travel speed on level, paved roads of approximately 14 mph when tested in accordance with 4.4.1.8.

3.28. Reserved.

3.29. Treatment and Painting. Cranes 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 (preferably a urethane type) applied to a dry film thickness of 3 mils minimum. 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 crane, not normally painted with a finish coat, shall be cleaned and protected in accordance with good commercial practice. Cables, sheaves, tires, plastics, 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, wire harnesses and chrome plating shall not be painted and shall be adequately protected or masked from overspray. The finish color shall be yellow in accordance with FED-STD-595, color chip 13538. Shipboard cranes shall have the entire crane, including exterior surface of the boom painted yellow.

3.30. Workmanship. The crane 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 crane, before and after painting, shall be clean and free from sand, rust, dirt, fins, pits, spurs, risers, scale, flux, oil, grease, 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.

3.31. Welds. Structural and non-structural 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 D14.3, and ASME Section IX.

3.32. Vehicle Marking. Each crane shall be marked in black enamel block letters and numbers as specified herein. Enamel paint or vinyl black decals are acceptable.

3.32.1. Weight Test Label and Vehicle Weight. The safe working load (SWL) and vehicle weight (VW) shall be clearly printed in 2-inch minimum letters and numbers on both sides of the crane body. In addition, these markings must be clearly in view of the operator, using the largest lettering size that will fit on the area. (Example: SWL 10,000 LBS. VW 10,000LBS.)

3.32.2. Brake Linings: The words "Non-asbestos brake linings used. Replacements to be non-asbestos" shall be printed in one-inch high letters on the cranes cab.

3.32.3. Registration Number: Assigned USN registration number for each crane shall be printed in three inches high located on each side and on rear of crane.

3.32.4. Tire Pressure. For pneumatic tired cranes, the air pressure for each tire shall be located on each side of the crane near the applicable tire, in one inch high numerals.

3.32.5. Emergency Lowering. Instructions for emergency lowering procedures in the event of system failure shall be provided in the operator’s cabin.

3.32.6. Supplementary Markings. Supplementary markings and load handling symbols as specified in ASME B30.5 are required.

3.32.7. Slinging and Tiedowns. Slinging and tiedown markings shall be in accordance with MIL-STD-209 with the exception that 3/4 inch lettering size is acceptable.

3.32.8. Safety Warning. Safety warning “NO RIDERS" shall be marked on the on each side of the cranes cab.

3.32.9. Fuel Type. Fuel type shall be 1 inch high located near fuel tank filler.

3.32.10. Shipboard Marking. Cranes shall be identified with the words "SHIPBOARD USE APPROVED", 1-1/2 inch high located on each side of cranes cab.

3.32.11. Paint Marking. Crane shall be marked with "PAINTED WITH LEAD AND CHROMATE FREE PAINT BY (manufacturer), month and year" in one-inch high letters on each side of the cranes cab.

3.32.12. Vehicle Weight. The crane's weight without load shall be marked on each side of the cranes cab in 2" high numbers and 3/4 inch high on mast cross bar in view of operator. Example: VW- 27000 pounds.

3.32.13. Outriggers. The outriggers shall be clearly marked, in the most visible location, with “CAUTION” in ¾- inch high letters and numbers.

3.32.14. Hydraulic Tank Filler. The hydraulic tank fill shall be clearly marked with ¾-inch minimum letters and numbers.

3.33. Data Plates.

3.33.1. Identification Plate / Label. A manufacturer’s identification plate shall be furnished and installed, by the manufacturer, on the crane in accordance with MIL-STD-130. In addition to this requirement, the identification plate shall contain, at a minimum, the manufacturer’s make, model, unit serial number, nomenclature, contract number, rated hoisting capacity in pound units, USN registration number, shipping weight, cube dimension, name or stamp of government inspector, date shipped, technical manual stock number, warranty expiration date and manufacturer’s name and address.

3.33.2. Operator's Cab Capacity Plate - A capacity plate shall be installed inside the operator's cab such that it is visible to the operator when operating the crane. The plate shall be fabricated in accordance with MIL-STD-130, with the exception that the lettering shall be reduced proportionally. Capacity plate shall include load ratings for both On Land and Shipboard operation.

3.33.3. Operational data plate. A data plate shall be mounted on the crane swing column instructing the operator of the correct procedure to follow in the event there is an electrical failure. All operational and caution data plates shall be mounted in locations readily visible to the crane operator. Plates shall contain all necessary warning type information to assure proper operation including the crane's rated lifting limitations. The operational data plate for operating the crane in case of a power failure shall include the "model number", "part number 11651265," "serial number" (to be stamped in), "capacity 2,500 pounds" at any boom angle (EXAMPLE), as well as any appropriate instructions.

3.34. Walkway coating. Floor plates and step surfaces shall be coated with a nonslip-coating compound, or be furnished with a nonslip metal or tread plate surface.

3.35. Slinging and tie down provisions. Each crane shall be provided with lifting and tiedown attachments that will withstand the loads indicated in MIL-STD-209. Also, tiedowns shall withstand Grade A HI-shock as specified herein (3.41).

3.36. Wheels and tires.

3.36.1. Wheels. Wheels (rims) shall be in accordance with the Tire and Rim Association Yearbook.

3.36.2. Tires. All tires shall be new and unused, wide base off-the-road type, and of identical size and construction. The tires shall be pneumatic, low pressure, tubeless tires. Tire loadings shall be in accordance with the TRA Yearbook and the tire manufacturer's published literature. Valves and caps shall be in accordance with the TRA Yearbook. Hydroinflated tires are not acceptable.

3.37. Wheel guards. Wheel guards shall be furnished at all four wheels to provide protection for the operator from material being thrown radially off the rotating tires. Each fender shall structurally support a weight of 300 pounds without evidence of damage.

3.38. Deck loading. The crane shall be demonstrated by picking a minimum load of 10,000 lb (threshold) with an objective load of 30,000 lbs., when tested in accordance with 4.4.1.15, Test Method No. 11. In no case shall deck loading exceed 250 psi. The minimum width dimension measured across the area of the footprint (tire contact area) of each individual tire shall not be less than 5.5 inches.

Cranes complying with deck loading criteria with load capacities above the threshold value are considered to be of added value to the Navy in direct relation to their proximity to the stated objective value.

3.39. Towing hitch. A pintle-type towing hitch shall be installed at the center rear and center front of the cranes base, with the center of the hitch opening 22 to 30 inches above ground level. The pintle shall be capable of sustaining a rearward, horizontal force of at least 33% of the unladen vehicle weight of the crane when tested in accordance with 4.4.1.17, Test Method No. 13. Two lugs, one positioned on each side of the pintle, shall be installed for securing safety chains; minimum lug opening diameter shall be three inches. The hitch shall be in accordance with A-A-52464 and A-A-52550.

3.40. Electromagnetic Interference. The crane shall conform to the radiation and susceptibility EMI requirements of MIL-STD-461. For electric field radiated emissions, procedure RE102 shall be used with the topside limit shown in Figure RE102-1 over a frequency range of 10 KHZ to 1 GHZ, or 10 times the highest intentionally generated frequency up to 18GHz, whichever is greater. For magnetic field emissions, procedure RE101 shall be used with the limit shown in Figure RE101-2. For susceptibility to electric fields, procedure RS103 shall apply with a frequency range from 2 MHZ to 18 GHZ at a limit level of 200 volts per meter. Additionally, the crane shall be able to safely execute its mission while exposed to the flight deck electric field environment from Table 1 of MIL-STD-464.

3.41. H.I. (High-Impact) Shock Requirement. The crane shall be designed to operate as specified herein when subjected to MIL-S-901 TYPE & Grade A, “CLASS I-Modified” HI Shock in accordance with 4.4.1.28.

3.41.1. Cab Safety Glass: All cab laminated safety glass shall withstand HI-Shock testing to the extent that it will meet the criteria identified in 4.4.1.28.1.

3.42. Resistance to Saline Atmosphere. The crane shall be designed in accordance with MIL-STD-810 to withstand the corrosive effects of saline atmosphere without any loss or deterioration of performance and without sustaining evidence of harmful corrosion, loss of mobility of parts and an inability to disassemble parts for service…