DRAFT- TK-2111A - DFP

DESCRIPTION FOR PURCHASE

TOOL AND EQUIPMENT KIT, SMALL ARMS

DFP 583

1. Background.

1.1. Background. This Description for Purchase (DFP) establishes the detailed requirements for the TOOL AND EQUIPMENT KIT, SMALL ARMS – NSN: XXXX-XX-XXX-XXXX, Model Number: TK-2111A, CAGE: XXXXX, TAMCN: E7900, USMC ID: XXXXXX, hereafter called TK-2111A. The TK-2111A is a tool kit used for the repair of small armaments. The TK-2111A supports O-level maintenance activities and is intended to serve as an individual Marine’s tool set when repairing small armaments. The tools and equipment are placed in a ruggedized tool case that is mobile and deployable by a single maintainer. Figure 1 contains images of two styles of acceptable tool cases.

Figure 1. TK-2111A: Acceptable tool case styles

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

Beneficial comments and any pertinent data which may be useful in improving this document should be addressed to: HQ ARDEC, RDAR-EIL-TC, Rock Island IL 61299-7300.

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DRAFT

2. Applicable documents.

2.1. General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements, and documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2. Government documents.

2.2.1. Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS).

SPECIFICATIONS

FEDERAL

A-A-3068 - Stones, Sharpening

A-A-50271 - Plate, Identification

GGG-C-313D - Chisel, Hand, Cape, Diamond Point, Cold, Round Nose and Side Cutting

GGG-H-33B - Hammers, Hand and Mallets, Surface Protective; Holders and Adapters, Inserted Hammer Face, and Faces, Hammer, Inserted

GGG-H-86C - Hammer, Hand

GGG-P-831F - Punches, Center, Drive Pin, Aligning and Prick

GGG-R-791H - Rule, Measuring

GGG-T-870A - Tweezers, Craftsmans

STANDARDS

FEDERAL

FED-STD-595 - Colors Used in Government Procurement

MILITARY

MIL-STD-129 - Department of Defense Standard Practice, Military Marking for Shipment and Storage

MIL-STD-130 - Department of Defense Standard Practice, Identification marking of U.S. Military Property

MIL-STD-662 - V50 Ballistic Tests for Armor

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MIL-STD-1472 - Department of Defense Design Criteria Standard, Human Engineering

MIL-G-4412 - Gage, Thickness

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094).

2.3. Non-government publications. The following document(s) form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents that are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z535.4 - Product Safety Signs and Labels

ANSI Z87.1 - Occupational and Educational Personal Eye and Face Protection Devices

(Application for copies should be addressed to the American National Standards Institute, 11 W.

42nd Street, New York, New York 10036.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B18.3 - Socket Cap, Shoulder, and Set Screws, Hex and Spline (Inch Series)

ASME B107.1 - Socket Wrenches, Hand (Inch Series)

ASME B107.5M - Socket Wrenches, Hand (Metric Series)

ASME B107.8 - Adjustable Wrenches

ASME 107.10 - Handles and Attachments for Hand Socket Wrenches

ASME B107.11 - Pliers: Diagonal Cutting and End Cutting

ASME B107.13 - Pliers, Long Nose

ASME B107.19 - Pliers: Retaining Ring

ASME B107.18 - Pliers, Wire Twisting

ASME B107.23 - Pliers: Multiple Position, Adjustable

ASME B107.66 - Ratcheting Box Wrenches

ASME B107.14 - Hand Torque Tools

ASME B107.15 - Flat Tip Screwdrivers

ASME B107.30 - Cross Tip Screwdriver

(Application for copies should be addressed to the American Society of Mechanical Engineers, Information Central Orders/Inquires P.O. Box 2300, Fairfield, New Jersey 07007-2300)

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AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM

INTERNATIONAL)

ASTMD 5118 - Fabrication of Fiberboard Boxes

ASTM D 5271 - Determining the Aerobic Biodegradation of Plastic Materials in an Activated-Sludge- Wastewater-Treatment System

ASTM D 5338 - Determining Aerobic Biodegradation of Plastic Materials Under Controlled Composting Conditions

ASTM D 5511 - Standard Test Method for Determining Anaerobic Biodegradation of Plastic Materials Under High-Solids Anaerobic- Digestion Conditions

(Application for copies should be addressed to the ASTM International 100 Barr Harbor Drive, P. O. Box C700. West Conshohocken, PA, 19428-2959)

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

ISO/IEC 16022 - Information Technology - International symbology specification – Data Matrix

(Application for copies should be addressed to the International Organization for Standardization (ISO), 1, ch. De la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland)

2.4. Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document; however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. Requirements.

3.1. Disclaimers and Definitions.

3.1.1. Pictorial representations. The figures included in this DFP represent the government’s proposed design concept and all images are property of the US Army. The controlling requirements for the TK-2111A are the text requirements of this DFP; the figures are included only for additional clarity. It is the responsibility of the offeror to ensure that each item offered meets all of the requirements related to the item. The citation of trade or manufacturers’ names does not constitute an endorsement by the Government.

3.1.2. Item requirement. The item description is the controlling requirement. It is the responsibility of the offeror to assure that each item offered meets all of the requirements related to the item, including the industrial quality portion.

3.1.3. Resale items. Many manufacturers do not sell their items directly. The items listed in Table IV from these types of sources are not treated differently than from sources that will direct-sell. Therefore, some items on the list may have to be obtained from a resale source, rather than the direct manufacturer.

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3.1.3.1. Manufacturer information. If resale sources are utilized, the information provided about individual tools (such as CAGE code and part number) shall reflect the individual item’s manufacturer, not the reseller that sold the tools or the tool load provider.

3.1.4. Brand name or equal. The items identified in Table IV of this DFP shall be identified as “Brand Name” or “Equal” in accordance with FAR 11.104 and FAR provision 52.211-6.

Offerors may offer the brand name items or equivalent items from other manufacturers determined to be equal to the specified products. Equal items shall meet the salient physical, functional, and performance characteristics of the brand name items to be acceptable for award.

The citation of trade or manufacturers’ names does not constitute an endorsement by the Government.

3.1.4.1. Brand name. An offered item shall be considered “Brand Name” if the item offered is the exact manufacturer and part number referenced in Table IV.

3.1.4.2. Equal. Offerors are not restricted to the listed manufacturer/part number. Offerors may offer an equivalent item provided that the offered item meets the salient physical, functional, and performance characteristics of the brand name items. The warranty provided for an equivalent item must be equal in terms and length of the warranty of the brand name items.

3.1.4.3. Representative Sample. The offeror shall submit a complete set of all tools in the proposal as a representative sample for evaluation by the government.

3.2. Construction/workmanship.

3.2.1. Industrial quality tools. All items from Table IV supplied with this set shall be industrial quality.

3.2.1.1. Industrial quality tools definition. For the purposes of this procurement, the term “industrial quality tools” versus household-use tools or general purpose tools are defined as tools that are commercially marketed and manufactured for constant, rigorous, industrial or professional environment use, and that have demonstrated market acceptance.

3.2.1.2. Use. Industrial quality tools are used primarily by skilled professionals and technicians in such areas as machine shops, automotive maintenance and repair facilities, aircraft maintenance and repair facilities, industrial automotive assembly plants, fleet maintenance facilities and airline service facilities. The tools will be used for specialized applications in an environment of virtual constant use, (i.e. around-the-clock 8 hour shifts), with applications requiring high torque, low slippage, and strict tolerances.

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3.2.1.3. Market acceptance. Market acceptance is demonstrated by the component having a higher percentage of sales to industrial/professional customers than to retail or government customers. Advertising or marketing literature that indicates “professional grade” or “industrial quality”, or merely stating that an item is “professional grade” or “industrial quality” is insufficient to establish industrial/professional quality since these are terms for which there is no generally acceptable definition. A claim that an item is manufactured to an industry consensus standard is also insufficient to establish industrial or professional quality. If the offered components have not achieved industrial/professional market acceptance; or have not been satisfactorily supplied to the Government under current or recent contracts for the same or similar requirements, then the contracting officer may require offerors to provide evidence of market acceptance in the professional or industrial market. Evidence of acceptance by industrial/professional customers includes sales to fleet operators, distributors, contractors, industrial and professional users, and sales to distributors who retail exclusively to the professional or industrial market.

3.2.2. Construction. The quality of workmanship imparted to the TK-2111A shall be equal to or exceed what is typically provided in commercial products of this type. The TK-2111A, when presented for acceptance, shall have been manufactured with skill and care; shall be uniform, neat, and clean; and shall be free from irregularities and anomalies which degrade form, fit, function, performance or appearance.

3.2.3. Consistency. Each issued set (as specified in Table IV) shall consist of the same brand.

This will ease inventory responsibilities, as well as provide consistency through each individual set. Therefore, each set shall consist entirely of the same manufacturer and same brand. See Table I for an example of a set and of non-set items. Table I contains Line Items 20 through 22.6 of the tool list. In Table I, line items 24, 25 and 26 (reflector tool, machinist ruler and sharpening stone set) may be of different brands, but all lines within Line Item 26 (26.1 through 26.7) shall be of the same brand.

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Table I. Example of sets

Line Item

Part Number Manufacturer Item Description U I

QT

Y

Warranty Type

24 084-174-250 Brownells Reflector Tool, Chamber; 0.25 +/- 1.0 inch diameter E A

1 LIFE

25 RULER600 Snap-on Rule, Machinist, steel, 6 +/- 1.0 inch E A

1 LIFE

26 Norton Sharpening Stone Tool Set S E

26.1 HS4 Norton

Round Edge, hard translucent, Ultra Fine, 4 inch X 1-3/4 inch X 3/8 inch X 1/8 inch

Sharpening Stone

E A

LIFE

26.2 HF813 Norton

Round File, hard translucent, Ultra Fine, 3 inch X 1/4 inch Sharpening Stone E A

LIFE

26.3 HF13 Norton

Square File, Hard translucent, Ultra Fine, 3 inch X 1/4 inch Ultra Fine Sharpening Stone

E A

LIFE

26.4 FF334 Norton

Half round, aluminum oxide, 4 inch X 3/8 inch Fine Sharpening Stone E A

LIFE

26.5 HF43 Norton

Square, Hard translucent, 3 inch X 1/2 inch, Ultra Fine Sharpening Stone E A

LIFE

26.6 FF46 Norton

Square, aluminum oxide, 6 inch X 1/2 inch, Fine Sharpening Stone E A

LIFE

26.7 03-7251 C.H. Ellis Pouch, roll-up, 7-pocket E A

LIFE

3.2.4. Interchangeability. Each TK-2111A shall be constructed in such a manner as to allow interchangeability of all like portions (i.e. drawer for drawer, tool for tool, handle for handle, etc.) of the tool set. The tool cases shall also be identical, with the exception of the unique information on the item identification plate.

3.2.5. Government furnished material (GFM).

3.2.5.1. Gage box. The offeror shall provide a location that will hold the gage box which has been identified in Drawer #3. A single empty gage box will be furnished as GFM to verify the size of the storage location. The offeror is not responsible for providing this gage box and its associated gages with every kit ordered. The gage box will be returned to the government with the delivery of the initial production TK-2111A.

3.2.5.2. Hand tools. The list of tools in Table II will be supplied as GFM. One set of GFM tools will be provided for each TK-2111A ordered. The drawer locations for the GFM tools are listed in Table IV.

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Table II. Government furnished material

Item Number

Part Number

Manufacturer Item Description UI QTY

19 Warrensville Hand File Set

19.1 16046 Warrensville Round Hand File, Bastard Cut, 6 inch overall length EA 1

19.2 12546 Warrensville Flat Hand File, Bastard Cut, 6 inch overall length EA 1

19.3 13046 Warrensville Half-round Hand File, Bastard Cut, 6 inch overall length EA 1

19.4 18046 Warrensville Three-square Hand File, Bastard Cut, 6 inch overall length EA 1

19.5 30204 Warrensville Wooden Handle, Screw-on, fits all 6 inch hand files EA 1

20 88250 Warrensville Set, File, Swiss Needle, 13 pcs. SE 1

20.1 71032 Warrensville Handle, File, Plastic, Blue EA 1

20.2 80155 Warrensville File, Swiss, Needle, Marking, 5.5 inch length, “0” cut EA 1

20.3 80065 Warrensville File, Swiss, Needle, 3-Square, 5.5 inch length, “0” cut EA 1

20.4 80115 Warrensville File, Swiss, Needle, Barrette, 5.5 inch length, “0” cut EA 1

20.5 80085 Warrensville File, Swiss, Needle, Round, 5.5 inch length, “0” cut EA 1

20.6 80035 Warrensville File, Swiss, Needle, Flat, 5.5 inch length, “0” cut EA 1

20.7 80015 Warrensville File, Swiss, Needle, Equaling, 5.5 inch length, “0” cut EA 1

20.8 80105 Warrensville File, Swiss, Needle, Slitting, 5.5 inch length, “0” cut EA 1

20.9 80055 Warrensville File, Swiss, Needle, Half-Round, 5.5 inch length, “0” cut EA 1

20.10 80135 Warrensville File, Swiss, Needle, Joint, 5.5 inch length, “0” cut EA 1

20.11 80125 Warrensville File, Swiss, Needle, Knife, 5.5 inch length, “0” cut EA 1

20.12 80095 Warrensville File, Swiss, Needle, Crossing, 5.5 inch length, “0” cut EA 1

20.13 80075 Warrensville File, Swiss, Needle, Square, 5.5 inch length, “0” cut EA 1

27.1 TM6 Melco

Box Spanner, tubular, 100mm length, 10 X 11 mm double ended female hex head. Able to accept a tommy bar

EA 1

27.2 T32 Melco Tommy Bar; 1/4 inch diameter, 5 inch lg EA 1

SPK-

SpecTool Ratcheting Screwdriver and bit set SE 1

3.3. Ruggedized tool case. Each individual TK-2111A shall be contained within a single ruggedized tool case. The ruggedized tool case offered shall meet all requirements stated in sections 3.4 or 3.5 and exhibit all demonstrations in Section 4.

3.3.1. Tool case style. Two acceptable styles for the ruggedized tool case are a top tray style and a single door style. Only one tool case style shall be provided. The brand name for the top tray style is the Pelican 0450. The brand name for the single door style is the Snap-on KMC18. The requirements for the top tray style tool case are described in section 3.4 and the requirements for the single door style tool case are described in section 3.5.

3.4. Top tray style tool case. The TK-2111A may be contained in a top tray style tool case. For additional information about the tool case styles, see 3.3.1.

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3.4.1. Frame of reference. The frame of reference is as follows: the front of the TK-2111A is the locked front panel; the rear is opposite the front exhibiting the telescoping handle and the wheels.

The sides are defined by exhibiting the lifting handles. For further clarity see Figure 2.

Figure 2. Top tray style frame of reference (shown in the upright position)

3.4.2. Tool case design. The design of the ruggedized tool case shall provide a mobile tool case configuration with a top lid that opens to expose a tool bay and a front lid that opens to expose drawers. When the tool case is open and sitting on a level work surface, with the top lid open and the front lid open, neither lid shall prevent access to any item or drawer of the tool case.

3.4.2.1. Materials. To meet durability requirements, the ruggedized tool case shall be constructed of an injection molded polypropylene copolymer.

3.4.2.2. Hardware. In order to meet corrosion prevention and maintenance requirements, all hardware used in the construction of the tool case shall be stainless steel. This includes all screws, pins, bolts, rivets, and any latching, locking, and sealing hardware including hinges. A certificate of conformance shall be sufficient demonstration that the tool case complies with this requirement.

Top Side

Rear

Front

Side

US Army Photo

2012-01-03

3.4.2.3. Latching hardware. To meet weather-tightness requirements, the tool case shall exhibit no fewer than 4 double throw latches consisting of 2 butterfly latches and 2 non-butterfly latches.

These latches shall be placed approximately as shown in Figure 3 or as required to meet the weather-tightness requirement in 3.10.2.

Figure 3. Latches

3.4.2.4. Lifting handles. The tool case shall utilize handles for lifting and carrying the tool case.

The handles shall be integral to the tool case and provide an even load. The handles shall be capable of laying flat against the side of the tool case when not in use, so as not to interfere with stacking. For further clarity see Figure 4.

3.4.2.5. Two person lift. Due to the weight of the fully loaded tool case and the mission profile in accordance with 3.9, lifting the tool case is expected to require 2 persons. Therefore, to comply with the human engineering requirements of MIL-STD-1472, handles for 2 people are required.

Furthermore, all marking requirements in MIL-STD-1472 shall be followed: both the number of persons required to lift the case and the weight of the case shall be clearly marked on the exterior of the case. For additional information see 3.8.3.

Butterfly latch

Non-butterfly latch US Army 3D Model

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Figure 4. Handle locations

3.4.2.6. Movement aids. The tool case shall include a set of permanently attached wheels and a telescoping handle that will aid in movement of the case.

3.4.2.6.1 Wheels. The wheels shall provide the ability to roll the tool case around on paved, hard floor, grass and gravel surfaces. The wheels shall be attached and integrated into the design of the tool case. The presence of the wheels shall not interfere with the stacking ability.

3.4.2.6.1.1 Wheel dimensions. Each wheel shall be no less than 1.9 inches wide X 2.9 inches diameter.

3.4.2.6.1.2 Wheel drop resistance. The wheels, axles and any wheel mounting brackets shall be able to withstand being rolled over bumps and cracks in pavement or gravel, and shocks incurred when the fully loaded tool case is dropped onto the wheels on hard concrete or asphalt from a height of 36 inches – 0 inches, + 2 inches. Any loss of functionality shall be considered a failure of this requirement.

3.4.2.6.1.3 Wheel operation. The wheels of a fully loaded tool case shall be able to be rolled over a gravel surface that contains 0.75 inch and smaller diameter gravel for 100 feet – 0 feet, + 5 feet without requiring replacement. The wheels shall roll smoothly and shall not bind.

3.4.2.6.1.4 Wheel durability. The wheels of a fully loaded tool case shall be able to be rolled over a concrete or asphalt road surface for 10 miles – 0 miles, + 0.1 miles without requiring replacement. The wheels shall roll smoothly and shall not bind.

3.4.2.6.1.5 Wheel replacement. The wheels shall be able to be replaced by a single user in under 10 minutes using only tools from the tool load. No access to the interior of the tool case for wheel replacement shall be allowed. The tool case shall remain weather-tight after wheels are replaced. No sealant shall be required to maintain weather-tightness for wheel replacement.

Additional lifting handle

Lifting handle

US Army Photo

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3.4.2.6.2 Telescoping handle. The tool case shall utilize a telescoping handle as shown in Figure

5. The handle shall be of suitable size to be utilized by all members of the Marine Corps target population (see 5.4). Use of the handle shall not require the user to stoop over. The handle used to roll the tool case shall not be the same handle that is utilized for lifting and carrying the tool case.

Figure 5. Telescoping handle and wheels

3.4.2.6.2.1 Side slope. When the fully loaded tool case is pulled by the telescoping handle over a 20º (36.4%) side slope, the tool case shall not tip over or become unstable while being pulled on this slope by all members of the Marine Corps target population (see 5.4).

3.4.2.6.2.2 Telescoping handle length. The telescoping handle shall exhibit a length of no less than 41 inches measured from the bottom of the tool case to the lowest point of the hand grasp.

For further clarity see Figure 5. (Note: the brand name for the top tray tool case does not meet this requirement). The telescoping handle length shall not allow the fully loaded tool case when pulled by that handle to contact the foot of all members of the Marine Corps target population (see 5.4) when walking.

3.4.2.6.2.3 Telescoping handle impact. The telescoping handle shall withstand repeated use without deforming or becoming unstable. When a fully loaded tool case with its telescoping handle fully extended and in the vertical position is caused to tip over with the end of the handle impacting against a solid stop that is 3 inches taller than the floor, there shall be no permanent deformation or damage to the handle or tool case that would render the tool case or handle inoperable or unusable. For further clarity see Figure 6.

Telescoping handle

Wheels

41 inches

US Army Photo

2012-01-03

Figure 6. Telescoping handle impact

3.4.3. Dimensions. The exterior envelope dimensions of the tool case shall be no greater than 24 inches X 15 inches X 18 inches. These dimensions shall include all handles, latches, hinges, feet, stacking features, and all items attached to the tool case. See Figure 7 for a tool case that meets these requirements.

Figure 7. Tool case

3.4.4. Color. The color of the tool case shall be subdued black (color chip number 37031 in accordance with FED-STD-595).

3.4.5. Finish. The exterior of the tool case shall be a matte finish, with no sharp projections or protrusions. The exterior of the tool case shall not exhibit any reflective surfaces.

3.4.6. Stacking. The design of the tool case shall permit stacking of tool cases. The placement of handles, clasps, or other features shall not interfere with the ability to stack tool cases. When four fully loaded tool cases are stacked, a 20.0 pound – 0 pounds, + 5 pounds tipping force applied to the top of the topmost tool case in any direction shall not cause any of the tool cases to fall.

24 inches Max

US Army Photo

15 inches Max.

18 inches Max

US Army Drawing

2012-01-03

3.4.7. Crush resistance. The tool case, when closed, latched and in its normal resting position shall protect its contents from damage. It shall withstand, without damage or permanent deformation to itself, a load consisting of three other identical fully loaded tool kits (including the tools) stacked on top of the case for 5 days. After the removal of the three other kits, the kit shall exhibit no deformation or damage.

3.4.8. Impact resistance. When fully loaded, closed, latched and placed in its normal resting position in a room temperature environment, the kit shall withstand impacts from dropped objects. At a minimum, it shall withstand an impact from a steel bar weighing 3.0 pounds – 0 pounds, + 0.25 pounds, with a cross section of 3/16 inch ± 0.016 inches by 1 inch ± 0.062 inches and edge radii of 1/16 inch ± 0.016 inches. This bar shall have been dropped in free fall from a height of 96 inches – 0 inches, + 2 inches and shall have landed narrow end down on the lid of the kit. The kit shall absorb the blow (bar impact) without suffering permanent deformation to its general overall configuration beyond superficial denting to the exterior of the tool case. The impact shall not cause penetration of the lid by the steel bar, or cause any holes in the tool case exterior.

3.4.9. Rough handling. To mimic the kit accidently being dropped off the bed of an MTVR, a kit fully loaded with tools shall withstand a drop test from a height of 60 inches – 0 inches, + 2 inches onto a level concrete surface. The kit shall then withstand being rolled over on the floor, 360º, four times, once over each lower edge of the tool case (when set in the upright position), without displacement of any of the retained tools and without sustaining any deformation or damage to the kit.

3.4.10. Locking and tool case security. The tool case shall be able to be locked using a single padlock with a shackle diameter of 0.343 inches ± 0.040 inches to provide physical security. The padlock shall be plainly visible on the exterior of the tool case.

3.4.10.1. Tool case lock. The padlock location for the tool case shall allow the padlock to be locked and remain within the exterior envelop of the tool case. This location shall allow the padlock to secure both the top tray lid and the front door of the tool case simultaneously.

3.4.11. Nylon tool bag storage. The nylon tool bag (Line Item 4) of the tool list found in Table IV shall be stored in the top tray of the tool case as shown in Figure 8. This tool bag does not require retention or restraining features.

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Figure 8. Nylon tool bag storage

3.5. Single door style tool case. An offeror quoting a single door style tool case shall provide evidence the tool case conforms to all requirements listed in section 3.5.

3.5.1. Frame of reference. The frame of reference is as follows: the front of the TK-2111A is the locked front panel; the rear is opposite the front exhibiting the telescoping handle. The sides are defined by exhibiting the lifting handles. The upright position is defined as exhibiting the front panel hinges located at the top of the box. For further clarity see Figure 9.

Figure 9. Single door style tool case frame of reference (shown in upright position)

Tool bag storage location

US Army 3D Model

Front

Top

Rear

Side

Side

US Army Photo

2012-01-03

3.5.2. Tool case design. The ruggedized tool case shall be designed with a front panel. This front panel shall be hinged along the top of the box. The hinge shall be designed such that the front panel will rotate up and lay flat on the top of the tool case in order to access the drawers when the tool case is in the upright position.

3.5.2.1. Materials. The ruggedized tool case shall be constructed of an injection molded polypropylene copolymer to meet durability requirements.

3.5.2.2. Hardware. In order to meet corrosion prevention and maintenance requirements, all hardware used in the construction of the tool case shall be stainless steel. This includes all screws, pins, bolts, rivets, and any latching, locking, and sealing hardware including hinges. A certificate of conformance shall be sufficient demonstration that the tool case complies with this requirement.

3.5.2.3. Latching hardware. To meet weather-tightness requirements, the tool case shall exhibit no fewer than 4 latches. These latches shall be a spring-loaded, four-bar linkage design. These latches shall be located as required to meet the weather-tightness requirement in 3.10.2. For further clarity see Figure 10.

Figure 10. Latches

3.5.2.4. Lifting handles. The tool case shall utilize handles for lifting and carrying the tool case.

The handles shall be integral to the tool case and provide an even load. The handles shall be capable of laying flat against the side of the tool case when not in use, so as not to interfere with stacking. The handles shall be capable of being used without the tool case rotating. See Figure 11 for further clarity.

Spring loaded, four-bar linkage latch

US Army Photo

2012-01-03

3.5.2.5. Two person lift. Due to the weight of the fully loaded tool case and the mission profile in accordance with 3.9, lifting the tool case is expected to require 2 persons. Therefore, to comply with the human engineering requirements of MIL-STD-1472, handles for 2 people are required.

Furthermore, all marking requirements in MIL-STD-1472 shall be followed: both the number of persons required to lift the case and the weight of the case shall be clearly marked on the exterior of the case. For additional information see Section 3.8.3.

Figure 11. Handle locations

3.5.2.6. Movement aids. The tool case shall include a set of permanently attached wheels and a telescoping handle that will aid in movement of the case.

3.5.2.6.1 Wheels. The wheels shall provide the ability to roll the tool case around on paved, hard floor, grass and gravel surfaces. The wheels shall be attached and integrated into the design of the tool case. The presence of the wheels shall not interfere with the stacking ability. The centerline distance between the wheels shall be 22.25 inches ± 0.25 inches.

3.5.2.6.1.1 Wheel dimensions. Each wheel shall be no less than 1.375 inches wide X 2.875 inches diameter.

3.5.2.6.1.2 Wheel drop resistance. The wheels, axles and any wheel mounting brackets shall be able to withstand being rolled over bumps and cracks in pavement or gravel, and shocks incurred when the fully loaded tool case is dropped onto the wheels on hard concrete or asphalt from a height of 36 inches – 0 inches, + 2 inches. Any loss of functionality shall be considered a failure of this requirement.

3.5.2.6.1.3 Wheel operation. The wheels of a fully loaded tool case shall be able to be rolled over a gravel surface that contains 0.75 inch and smaller diameter gravel for 100 feet – 0 feet, + 5 feet without requiring replacement. The wheels shall roll smoothly and shall not bind.

3.5.2.6.1.4 Wheel durability. The wheels of a fully loaded tool case shall be able to be rolled over a concrete or asphalt road surface for 10 miles – 0 miles, + 0.1 miles without requiring replacement. The wheels shall roll smoothly and shall not bind.

Lifting handle

Lifting handle

US Army Photo

2012-01-03

3.5.2.6.1.5 Wheel replacement. The wheels shall be able to be replaced by a single user in under 10 minutes using only tools from the tool load. No access to the interior of the tool case for wheel replacement shall be allowed. The tool case shall remain weather-tight after wheels are replaced. No sealant shall be required to maintain weather-tightness for wheel replacement.

3.5.2.6.2 Telescoping handle. The tool case shall utilize a telescoping handle as shown in Figure

12. The handle shall be of suitable size to be utilized by all members of the Marine Corps target population (see 5.4). The handle used to roll the tool case shall not be the same handle that is utilized for lifting and carrying the tool case. For further clarity see Figure 12.

Figure 12. Telescoping handle and wheels

3.5.2.6.2.1 Side slope. When the fully loaded tool case is pulled by the telescoping handle over a 20º (36.4%) side slope, the tool case shall not tip over or become unstable while being pulled on this slope by all members of the Marine Corps target population (see 5.4). Confirm that all wheels remain firmly on the surface while it is traversed. Any instability, tipping, or wheels lifting off the surface constitutes failure.

3.5.2.6.2.2 Telescoping handle length. The telescoping handle shall exhibit a length of no less than 41 inches measured from the bottom of the tool case to the lowest point of the hand grasp.

For further clarity see Figure 12. The telescoping handle length shall not allow the fully loaded tool case when pulled by that handle to contact the foot of all members of the Marine Corps target population (see 5.4) when walking.

Telescoping handle

Wheels

41 inches

US Army Photo

2012-01-03

3.5.2.6.2.3 Telescoping handle impact. The telescoping handle shall withstand repeated use without deforming or becoming unstable. When a fully loaded tool case with its telescoping handle fully extended and in the vertical position is caused to tip over with the end of the handle impacting against a solid stop that is 3 inches taller than the floor, there shall be no permanent deformation or damage to the handle or tool case that would render the tool case or handle inoperable or unusable. For further clarity see Figure 13.

Figure 13. Telescoping handle impact

3.5.3. Dimensions. The exterior envelope dimensions of the tool case shall be no greater than 24 inches X 15 inches X 18 inches. These dimensions shall include all handles, latches, hinges, feet, stacking features, and all items attached to the tool case. See Figure 14 for a tool case that meets these requirements.

Figure 14. Tool case

3.5.4. Color. The color of the tool case shall be subdued black (color chip number 37031 in accordance with FED-STD-595).

US Army Drawing

18 inches Max.

15 inches Max. 24 inches Max.

US Army Photo

2012-01-03

3.5.5. Finish. The exterior of the tool case shall be a matte finish, with no sharp projections or protrusions. The exterior of the tool case shall not exhibit any reflective surfaces.

3.5.6. Stacking. The design of the tool case shall permit stacking of tool cases. The placement of handles, clasps, or other features shall not interfere with the ability to stack tool cases. When four fully loaded tool cases are stacked, a 20.0 pound – 0 pounds, + 5 pounds tipping force applied to the top of the topmost tool case in any direction shall not cause any of the tool cases to fall.

3.5.7. Crush resistance. The tool case, when closed, latched and in its normal resting position shall protect its contents from damage. It shall withstand, without damage or permanent deformation to itself, a load consisting of three other identical fully loaded tool kits (including the tools) stacked on top of the case for 5 days. After the removal of the three other kits, the kit shall exhibit no deformation or damage.

3.5.8. Impact resistance. When fully loaded, closed, latched and placed in its normal resting position in a room temperature environment, the kit shall withstand impacts from dropped objects. At a minimum, it shall withstand an impact from a steel bar weighing 3.0 pounds – 0 pounds, + 0.25 pounds, with a cross section of 3/16 inch ± 0.016 inches by 1 inch ± 0.062 inches and edge radii of 1/16 inch ± 0.016 inches. This bar shall have been dropped in free fall from a height of 96 inches – 0 inches, + 2 inches and shall have landed narrow end down on the lid of the kit. The kit shall absorb the blow (bar impact) without suffering permanent deformation to its general overall configuration beyond superficial denting to the exterior of the tool case. The impact shall not cause penetration of the lid by the steel bar, or cause any holes in the tool case exterior.

3.5.9. Rough handling. To mimic the kit accidently being dropped off the bed of an MTVR, a kit fully loaded with tools shall withstand a drop test from a height of 60 inches – 0 inches, + 2 inches onto a level concrete surface. The kit shall then withstand being rolled over on the floor, 360º, four times, once over each lower edge of the tool case (when set in the upright position), without displacement of any of the retained tools and without sustaining any deformation or damage to the kit.

3.5.10. Locking and tool case security. The tool case shall be able to be locked using a single padlock with a shackle diameter of 0.343 inches ± 0.040 inches to provide physical security. The padlock shall be located on the centerline of the front surface of the tool case. The padlock shall be plainly visible on the exterior of the tool case.

3.5.10.1. Tool case lock. The padlock location for the tool case shall allow the padlock to be locked and remain secure within the exterior envelop of the tool case. This location shall be centered along the bottom edge of the door.

3.6. Internal storage.

3.6.1. Drawers. The ruggedized tool case shall exhibit drawers to contain the tool load in Table IV. The tool load shall be arranged to fit within five tool storage drawers and a removable top tray in the top tray style tool case as shown in Figure 15 or within six tool storage drawers in the single door style tool case as shown in Figure 16. Each drawer and the top tray (if proposed) shall be completely filled with a blow mold plastic tool retention system and shall include provisions that prevent the displacement of any tool, if that drawer is not currently being accessed.

2012-01-03

Figure 15. Top tray style tool storage drawer location

Figure 16. Single door style tool storage drawer location

Drawer 1

Drawer 3

Drawer 5

Drawer 2

Drawer 4

Top Tray

US Army 3D Model

Drawer 2

Drawer 4

Drawer 1

Drawer 6

Drawer 3

Drawer 5

US Army Photo

2012-01-03

3.6.2. Full extension. The drawers in both styles of the ruggedized tool case shall be full extension drawers. The drawer shall exhibit usable top surface dimensions of no less than 10.7 inches X 19.0 inches. For further clarity see Figure 17.

Figure 17. Drawer extension examples

3.6.2.1. Slide mechanism. The drawers shall extend using a slide mechanism. The sliders shall be replaceable using only tools in Table IV if damaged.

3.6.2.2. Drawer handle. The drawers shall exhibit a handle located symmetrically about the centerline of the front of the drawer. This handle shall be rectangular with a recessed area along the bottom of the handle for the user’s fingers to grasp the drawer. The handle recess area shall be 1 inch tall X 6 inches wide from the bottom surface of the drawer. For further clarity see Figure 18.

Full extension drawers

Partial extension drawers

US Army Photo

2012-01-03

Figure 18. Drawer handle examples

3.6.2.3. Drawer strength. Each drawer shall exhibit sufficient strength to support the weight of the tools in the drawer and not impede access of any other tool storage drawer. For further clarity see Figure 19.

Figure 19. Sagging drawer

3.6.2.4. Wheel clearance. The top tray style tool case drawer shall allow clearance for the wheels of the tool case. For further clarity see Figure 20.

Drawer interference

US Army Photo

Unacceptable drawer handle

Acceptable drawer handle

US Army Photo

2012-01-03

Figure 20. Top tray style drawer wheel clearance

3.6.2.5. Handle clearance. The single door style tool case drawers shall allow clearance for the telescoping handle of the tool case. For further clarity see Figure 21.

Figure 21. Single door style handle clearance

3.6.3. Drawer placement. Each tool storage drawer shall be located in the same location throughout the life of the contract.

3.6.4. Drawer designation. Each tool storage drawer shall be labeled with a drawer designation.

Handle clearance cutout

Wheel clearance cutout

US Army Photo

US Army Photo

2012-01-03

3.6.4.1. Drawer marking. The drawer designation shall exhibit a raised surface permanently marking the drawer. The font size of the letters shall be at least 0.25 inches tall. An example of this type of marking is found in Figure 22. The font on the labels shall conform to 3.7.2.4; note the font in the Figure 22 does not comply with the marking requirement. The information required on each label shall consist of the text shown in Table III.

Figure 22. Drawer label

Table III. Drawer label information

Top tray style drawer number

Top tray style drawer label

Single door style drawer number

Single door style drawer label

Top Tray TK2111A TOP TRAY 1 TK2111A DRAWER #1

1 TK2111A DRAWER #1 2 TK2111A DRAWER #2

2 TK2111A DRAWER #2 3 TK2111A DRAWER #3

3 TK2111A DRAWER #3 4 TK2111A DRAWER #4

4 TK2111A DRAWER #4 5 TK2111A DRAWER #5

5 TK2111A DRAWER #5 6 TK2111A DRAWER #6

3.6.4.2. Drawer marking location. The drawer marking shall be uniformly located on each drawer on the drawer handle. The drawer marking shall be symmetrical about the centerline of the drawer. The drawer marking locations shall be the same for all drawers. For further clarity on the drawer marking location see Figure 23.

US Army Photo

2012-01-03

Figure 23. Drawer marking location

3.6.4.2.1 Top tray label location. The top tray label shall be located on the front, at the mid-point of the tray. For further clarity see Figure 24.

3.6.4.3. Label material. The top tray label material shall consist of solid black label with white capital letters. The label shall be no less than 0.007 inch thick and shall resist peeling. The adhesive used to attach the label shall adhere the label to the surface for the economic life of the system, see paragraph 3.7.1.1. The letters on the label shall be no less than 0.25 inches of height.

Figure 24. Top tray label location

3.6.5. Tool retention system. Each drawer and the top tray (if proposed) shall consist of a blow mold plastic tool retention system. For an example of a blow molded plastic drawer, see Figure 25.

US Army 3D Model

Drawer marking location

US Army Photo

2012-01-03

Figure 25. Blow mold plastic tool retention system

3.6.5.1. Retention features. Each retention feature shall follow the contours of the tool and securely hold the tool in place through the expected transport and operation of the tool case.

Each contoured retention feature shall allow easy removal of the tool and shall include pick holes, cut outs, quarter turn retainers, snap-in retainers or recessed areas as necessary for tool removal. The preferred retention feature will be optimized for the individual tool. Approval of the retention features is required in accordance with 3.6.5.3.

3.6.5.1.1 Quarter turn retainers. An example of an acceptable tool retention feature is a quarter turn retainer. A quarter turn retainer is turned 90 degrees to release the tool. When the tool is returned to the drawer, the quarter turn retainer is turned back 90 degrees to hold the tool in place. An example of a quarter turn retainer is shown in Figure 26. Tools expected to exhibit quarter turn retainers include pliers, files, and tool rolls.

US Army Photo

2012-01-03

Figure 26. Quarter turn retainers

3.6.5.1.2 Rubber snap in retainer. An example of an acceptable tool retention feature is a rubber snap in retainer. A rubber snap in retainer is a rubber piece that is molded into the plastic tool retention system; snap in retainers using the same plastic material as the blow molded drawer are not acceptable. The rubber snap in retainer deflects to allow removal and replacement of the tool.

See Figure 27 for an example of a snap in retainer; note the snap in retainers in the figure are not rubber and are not acceptable.

Figure 27. Snap in retainer

3.6.5.1.3 Drawer tool retaining cover. An example of an unacceptable tool retention feature is a plastic cover. A plastic cover can be hinged at one side and held in place over the tools in the drawer by straps or some other method on the opposite side. This type of tool retention is not an acceptable retention method for this tool kit. See Figure 28 for an example of an unacceptable plastic drawer cover tool retention system.

Quarter turn closed Quarter turn open

Snap in retainer

US Army Photo

US Army Photo

2012-01-03

Figure 28. Plastic drawer cover tool retention

3.6.5.2. Specific tool placement. The drawers shall follow the proposed layouts in Appendix A.

If tools are sized differently from the proposed layouts, making drawer re-design inevitable, the first basis for placement would be to keep the same tools in the same drawers. If this is also impossible (i.e. the tool sizes grew too much to fit in the same drawers), then tools shall be arranged to have like tools with each other and to keep the overall scheme as similar as possible.

3.6.5.3. Government assistance. The task of organizing and retaining the tools within the blow mold plastic tool retention system shall be performed in conjunction with a Government representative. The Government’s representative will provide guidance and approval of the layout configuration and tool retention before the contractor commits additional resources to produce the layout.

Plastic drawer cover Plastic drawer cover open

US Army Photo

2012-01-03

3.6.5.4. Rapid inventory. The blow mold plastic tool retention system shall retain tools in position to provide for rapid inventory of the tool load and to maintain the position of tools under rough handling and shipping conditions. The TK-2111A shall be able to be inventoried in its entirety in less than 10 minutes.

3.6.5.5. Tool line art. The blow mold plastic tool retention system shall exhibit laser etched line art. The color of the laser etching shall contrast with the color of the blow mold plastic tool retention system. The line art color shall provide contrast underneath the tools to aid in rapid inventory and identification of missing tools. See Figure 29 for an example of a drawer organizer with line art. Note that the line art is clearly visible when the item is removed from the drawer.

3.6.5.5.1 Marine Corps stocklist numbering. The tool line art shall include the line number from the Marine Corps stocklist (SL-3). These tool line numbers will be generated after contract award. For an example of tool line numbers added to line art see Figure 29.

3.6.5.6. Tool retention system color. The drawer and the blow mold plastic tool retention system shall be black.

Figure 29. Tool organizer and contrasting image for missing tool

3.6.5.7. Material. The blow mold plastic tool retention system shall be composed of a blow mold grade of High Density Polyethylene (HDPE).

3.6.5.8. Rust inhibitor. The HDPE shall include a rust inhibiting additive. This rust inhibitor shall prevent the accumulation of rust on the tools during long-term storage. The HDPE shall not include any other additives that inhibit the performance of the rust inhibitor such as anti-static additives. The brand name for the rust inhibitor is Zerust® from Northern Technologies International Corporation.

3.6.5.9. Biodegradable. The HDPE shall include an additive that allows for the drawers to biodegrade when properly disposed. The additive shall allow the HDPE material to biodegrade in accordance with ASTM D 5511, ASTM D 5338 and ASTM D 5271. This will allow the drawers to be disposed in an anaerobic landfill, an aerobic compost facility or in an aerobic waste water system. The biodegrade additive shall not be activated until the HDPE is properly disposed.

Tool missing

SL-3 line number

Tool in place

US Army Photo

2012-01-03

3.7. Labels and markings

3.7.1. Plates and labels. All identification, warning, and instruction plates and labels shall be permanently affixed to the exterior of the tool case, see paragraph 3.7.1.1. They shall be resistant to deterioration caused by heat, cold, solar radiation, water, and petroleum products to the extent that they will remain intact and readily legible for the expected economic life of the TK-2111A.

Marking shall be accomplished in a manner that does not adversely affect the life and utility of the TK-2111A. All plates and labels shall be printed in the English language, and may be supplemented by graphical symbols.

3.7.1.1. Plate and label adhesive. All plates and labels shall exhibit an adhesive to attach the plates and labels to the tool case and the top tray. This adhesive shall be designed for optimum performance with low surface energy plastics. The brand name for this adhesive is 3M 300LSE Low Surface Energy Acrylic adhesive.

3.7.2. Item identification plate. A plate conforming to A-A-50271, Composition A, Class 2, and containing the following data, including the Unique Identification (UID) information from 3.7.2.1, shall identify each TK-2111A. The item identification plate shall be securely attached to the front exterior of the TK-2111A in a recessed location. For further clarity of the mounting location see Figure 30 for the top tray style tool case and Figure 31 for the single door style tool case. For further clarity of the information on the item identification plate, see Figure 32. The item identification plate shall not be produced without government concurrence.

a. Nomenclature: Tool and Equipment Kit, Small Arms

b. NSN: XXXX-XX-XXX-XXXX

c. Serial Number: (to be determined after award)

d. USMC TAMCN: E7900

e. Model #: TK-2111A

f. Contract #: (to be identified by contract/delivery order)

g. USMC ID: XXXXXX

h. CAGE Code: CAGE Code of manufacturer

i. Marine Corps Logo

j. UID information (see 3.7.2.1)

Figure 30. Top tray tool case identification plate location

Figure 31. Single door identification plate location

TK2111A

data plate

2-person lift warning label

TK2111A

data plate

2-person lift warning label

US Army Photo

US Army Photo

2012-01-03

Figure 32. Item identification example

3.7.2.1. Unique identification (UID). Each TK-2111A shall be marked with a UID containing a unique item identifier (UII) and the additional information listed in 3.7.2.2 that has machine-readable data elements that will distinguish it from all other like and unlike items. The required marking shall be applied to the item identification plate from 3.7.2. The UID data elements shall be contained in a Data Matrix ECC200 symbol in accordance with ISO/IEC16022. Marking shall conform to MIL-STD-130. The identifier shall remain intact and readily machine readable for the expected life of the set.