ATPD-2392G.pdf

ATPD-2392G (DRAFT)

ATPD-2392G

DRAFT 15 June 2015

PURCHASE DESCRIPTION

LIGHT CAPABILITY ROUGH TERRAIN FORKLIFT (LCRTF)

This specification is approved for use by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC), Research, Development and Engineering Command (RDECOM), Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This purchase description covers the Light Capability Rough Terrain Forklift

(LCRTF), equipped with a diesel engine and automatic or hydrostatic drive transmission.

1.2. Classification. The LCRTF is defined as a rough terrain forklift with two axles and four rubber tires. It shall have a diesel engine with an automatic or hydrostatic transmission. It shall be self deployable and used to handle light equipment and cargo over rough terrain, to enter, stuff and unstuff ISO shipping containers, load and unload tactical vehicles. The LCRTF shall not have outriggers.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 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 of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.1.1 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 cited in the solicitation or contract (see 6.2).

INTERNATIONAL STANDARDIZATION AGREEMENTS

STANAG-2010 - Military Load Classification Markings STANAG-2828 - Military Pallets, Packages and Containers STANAG-4074 - Auxiliary Power Unit Connections for Starting Tactical

Land Vehicles

FEDERAL STANDARDS

FED-STD-595/33446 - Tan 686A

COMMERCIAL ITEM DESCRIPTIONS

A-A-393 - Extinguisher, Fire, Dry Chemical (Hand Portable) A-A-52550 - Pintle Assembly, Towing, Manual Release, 18 000, 40 000, and 100 000 lbs Capacity A-A-52474 - Electrocoating Primer

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-53039 - Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant MIL-DTL-53072 - Chemical Agent resistant coating (CARC) System

Application Procedures and Quality Control Inspection 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-PRF-2104 - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service MIL-PRF-10924 - Grease, Automotive and Artillery MIL-PRF-11021 - Switch, Vehicular Lights: 28 Volt DC MIL-PRF-25017 - Inhibitor, Corrosion/Lubricity Improver, Fuel Soluble MIL-PRF-32143 - Batteries, Storage: Automotive, Valve Regulated Lead

Acid (VRLA) MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic

DEPARTMENT OF DEFENSE STANDARDS

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 Characteristics of Subsystems and Equipment

MIL-STD-464 - Electromagnetic Environmental Effects Requirements for Systems

MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests

MIL-STD-889 - Dissimilar Metals MIL-STD-913 - Requirements for the Certification of Sling Loaded

Military Equipment for External Transportation by Department of Defense Helicopters

MIL-STD-1179 - Lamps, Reflectors and Associated Signaling Equipment for Military Vehicles

MIL-STD-1366 - Transportability Criteria MIL-STD-1472 - Human Engineering

2.1.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

U.S. ARMY DEVELOPMENTAL TEST COMMAND TEST OPERATIONS

PROCEDURES

TOP 1-2-621 - Outdoor Sand and Dust Testing

CODE OF FEDERAL REGULATIONS (CFR)

29CFR1910.1200 - Occupational Safety and Health Administration (OSHA) Hazard Communication

ARMY RESEARCH LABORATORY PUBLICATIONS

ARL Approved Powder Coatings List

U.S. ARMY FIELD MANUALS

FM 3-11.5 - Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination

U.S. ARMY TARDEC PUBLICATIONS

TARDEC Petroleum, Oil and Lubricants Products Guide

U.S. ARMY TECHNICAL BULLETINS

TB 43-0142 - Safety Inspection and Testing of Lifting Devices

SURFACE DEPLOYMENT AND DISTRIBUTION COMMAND TRANSPORTATION

ENGINEERING AGENCY (SDDCTEA) PUBLICATIONS

PAM 70-1 - Transportability for Better Deployability

U.S. ARMY TACOM DRAWINGS

8448699 - Rifle, 5.56 MM, M16A1 - Outline Dimensions 87T0013 - Flatrack, M1077 9381436 - Rifle, 5.56 MM, M16A2 12258956 - Pressure Transducer, 10,000 PSI 12468780 - Container roll-in/Out Platform

(CROP)

12585018 - Chemical Agent Resistant Coating

System for Exterior and Interior Army Materiel

12597700 - Carbine, 5.56 MM, M4 (Envelope) 13229E8014 - Bracket Assembly, Rifle Stowage 13229E8016 - Bracket, Rifle Stowage

2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z535.3 - Criteria for Safety Symbols ANSI Z535.4 - Product Safety Signs and Labels

ASTM INTERNATIONAL

ASTM D975 - Standard Specification for Diesel Fuel Oils ASTM D610 - Standard Practice for Evaluating Degree of Rusting on

Painted Steel Surfaces ASTM D3359 - Standard Test Methods for Measuring Adhesion by Tape

Test

GENERAL MOTORS CORPORATION (GM)

GMW14872 - Worldwide Cyclic Corrosion Test

INDUSTRIAL TRUCK STANDARDS DEVELOPMENT FOUNDATION (ITSDF)

ITSDF B56.6 - Safety Standard for Rough Terrain Forklift Trucks

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

ISO 668 - Series 1 freight containers – Classification, dimensions and ratings

ISO 3287 - Powered industrial trucks - Symbols for operator controls and other displays

ISO 3449 - Earth-moving machinery - Falling-object protective structures

- Laboratory tests and performance requirements

ISO 3471 - Earth-moving machinery - Roll-over protective structures

- Laboratory tests and performance requirements

ISO 5010 - Earth-moving machinery - Rubber-tyred machines - Steering requirements

ISO 9533 - Earth-moving machinery - Machine-mounted forward and reverse audible warning alarm - Sound test method

SAE INTERNATIONAL

SAE J115 - Safety Signs SAE J185 - Access Systems for Off-Road Machines SAE J198 - Windshield Wiper Systems-Trucks, Buses, and Multipurpose Vehicles SAE J386 - Operator Restraint System for Off-Road Work Machines SAE J695 - Turning Ability and Off Tracking - Motor Vehicles SAE J847 - Trailer Tow Bar Eye and Pintle Hook/Coupler Performance SAE J942 - Passenger Car Windshield Washer Systems SAE J994 - Alarm - Backup - Electric Laboratory Performance Testing SAE J1165 - Reporting Cleanliness Levels of Hydraulic Fluids SAE J1176 - External Leakage Classifications for Hydraulic Systems SAE J1503 - Performance Test for Air-Conditioned, Heated, and

Ventilated Off-Road, Self-Propelled Work Machines

SAE J1535 - Performance Test for Windshield Defrosting Systems for Off-Road, Self-Propelled Work Machines

SAE J1614 - Wiring Distribution Systems for Construction, Agricultural, and Off-Road Work Machines

SAE J1708 - Serial Data Communications Between Microcomputer Systems in Heavy-Duty Vehicle Applications

SAE J1939 - Recommended Practice for a Serial Control and Communications VehicleNetwork

SAE J1939/13 - Off-Board Diagnostic Connector SAE J2334 - Laboratory Cyclic Corrosion Test SAE J2360 - Lubricating Oil, Gear Multipurpose (Metric) Military Use

2.3 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 Production Verification Testing (PVT). First article forklifts shall be subjected to PVT in accordance with section 4, and as may be required by the contract.

3.2 Materials.

3.2.1 Recycled, recovered or environmentally preferable materials. Recycled, recovered or environmentally preferable materials shall be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. Used, rebuilt or remanufactured components, pieces and parts shall not be incorporated into the LCRTF. All tires furnished shall be not more than six calendar quarters old from the date of cure of the rubber to the date of manufacture of the forklift.

3.2.2 Material corrosion control and performance. The LCRTF has an expected service life of 20 years, which will include varying or extended periods in corrosive environments involving one or more of the following: high humidity, salt spray, road de-icing agents, ground contact, gravel impingement, beach operations, fording, atmospheric contamination and temperature extremes (-40 to +140 degrees Fahrenheit (°F)). Only normal washing, scheduled maintenance (exclusive of paint touch up) and repair of accidentally damaged areas not a result of intended use, deficiency in design, materials, manufacturing or normal wear, shall be necessary to keep the corrosion or degradation prevention in effect. If the LCRTF is manufactured from inherently corrosion resistant materials, such as steel galvanized by hot dip or sheet coated to G- 90 or composite, corrosion design qualification is not required.

The prime contractor is liable for all the corrosion requirements and fixes during the warranty period of the system.

If dissimilar metals (including fasteners, hardware or other items) must be used, they shall be electrically insulated from one another to minimize or prevent galvanic corrosion.

The LCRTF shall be designed to avoid the collection and entrapment of water, debris, dirt, oils, maintenance fluids, and other matter in operational, storage, and transportation orientations. The system shall be designed to minimize cavities and crevices where water and debris may collect.

Where cavities are unavoidable, adequate drainage shall be provided. When drainage to an area outside of the system is not possible, the vehicle design shall facilitate drainage to a location or locations which are accessible for cleaning by the operator. Drainage of a cavity shall not adversely affect the corrosion performance of other components or items. Drainage shall not interfere with the structural integrity of the LCRTF.

3.3 Operating requirements.

3.3.1 Lift capacity. The LCRTF shall have a minimum load capacity of 5,000 pounds at a 24-inch load center (Threshold), 6,000 pounds (Objective), with the boom fully retracted, and the reach and capacity specified in 3.3.13.1. The LCRTF shall meet all PD requirements without outriggers.

3.3.2 Powertrain. The LCRTF shall be powered by a diesel engine. The LCRTF shall have an automatic or hydrostatic transmission. The transmission shall be fully synchronized to allow shifting between low and high speeds while the vehicle is in motion. The transmission shall be protected from damage when the operator moves or attempts to move the direction control to the opposite direction while the truck is in motion. The transmission shall be protected if the operator downshifts or attempts to downshift the transmission while the truck is traveling too fast for the speed range selected or attempted to be selected. (See 3.3.22 for TARDEC engine requirements.)

3.3.3 Steering and drive configuration. The LCRTF shall be rubber tired with two axles, continuous 4 wheel drive or selectable 2-wheel and 4-wheel drive, and capable of 2-wheel and 4-wheel steering. The steering system shall provide control of the LCRTF while traveling at any speed up to the maximum attainable travel speed, and shall meet the requirements of ISO 5010.

The steer wheels shall be capable of being turned from extreme right to extreme left or vice versa in not more than six complete turns of the steering wheel at low idle speed. Emergency steering shall be required only if the LCRTF cannot be steered under the control of the operator in the event of engine or steering power source failure. If required, the emergency steering shall conform to ISO 5010 and the steering effort shall not exceed 50 lbs. During towing operations, the forklift shall track behind the towing vehicle. An indicator shall be provided on the instrument panel to inform the operator that the rear axle is properly aligned with the front when transitioning back into 2-wheel steering.

3.3.4 Personnel cab.

3.3.4.1 ROPS and FOPS. The LCRTF shall be equipped with a weather tight personnel cab which may be combined with the Roll Over and Falling Object Protective Structure (ROPS and FOPS). The ROPS and FOPS shall conform to ISO 3471 and ISO 3449, Level I.

3.3.4.2 Heater and defroster. A heater and defroster shall be provided for the personnel cab compartment, meeting the requirements of SAE J1503. The heater shall have the capability to raise the temperature of the personnel cab compartment, as defined by SAE J1503, by 72 °F within 1 hour after the heater is turned on, in temperatures down to-25 °F. The defroster shall meet the requirements of SAE J1535, Area C for loaders, at ambient temperatures down to -25 °F within 1 hour with operator in cab. The same percentage of the rear window area shall be defrosted within one hour.

3.3.4.3 Air conditioning. An air conditioner system shall be provided. The air conditioner system shall be capable of lowering the cab temperature to 80 °F, without solar load, within 1 hour, when the ambient temperature is 125 °F. The air conditioner system shall meet this requirement when tested in accordance with SAE J1503. The system shall use an environmentally friendly, commercial use refrigerant.

3.3.4.4 Windshield wipers. The windshield and rear window shall each be equipped with at least one wiper assembly in accordance with the performance requirements of SAE J198. A windshield washer shall be provided for both the windshield and rear window and shall be in accordance with the performance requirements of SAE J942. Fluid container(s) shall be located or designed to prevent fluid from spilling on the operator during operation, accident or rollover.

Lines shall be routed so that hose failure shall not result in fluid spray on the operator.

3.3.4.5 Steering wheel locking system. The forklift shall be equipped with a steering wheel locking system to prevent unauthorized use of the forklift. If a locking system is not integral with the steering column, a corrosion resistant flexible steel cable shall be furnished. The cable system shall be mounted in a location so as not to interfere with the operator performing normal operations. The cable shall be secured to the mounting point to prevent loss of the cable during normal operations. It shall be located to not damage gages and other instrumentation during locking and unlocking operations. When a padlock is used, the locking system shall accommodate a padlock shackle of 3/8-inch diameter.

3.3.5 Dimensions and Floatation.

3.3.5.1 Dimensions. The LCRTF length with the boom retracted shall not exceed

235 inches. The LCRTF width shall not exceed 80 inches. The LCRTF height with the boom fully lowered shall not exceed 82 inches.

3.3.5.2 Vehicle Floatation. The LCRTF shall have a Floatation Index (FI) of not more than 30 with the rated load in the carry position and no more than 33 without rated load in the carry position.

( ) ( )FI C P

P P P

A A A

KF R F R= − + −

−log . . .

.1 0 211 0 350 0 00710 0 0752 0 0402

0 0346

Where:

PF = Tire pressure, front (psi) PR = Tire pressure, rear (psi) P = Tire pressure, average = 1/2 (PF + PR) AF = Axle load, front (pounds) AR = Axle load, rear (pounds) A = Gross vehicle weight = AF + AR K = 53.75 + 0.000139A (for nonradial tires) K = 55.77 + 0.000032A (for radial tires)

C A

P R W D log . . .0 607 135 117

4 93

R = Tire ply rating W = Tire width (inches - as cited in tire size) D = Rim diameter (inches - as cited in tire size)

3.3.6 Weight (maximum). The curb weight of the LCRTF configured to meet all the requirements of this purchase description shall not exceed 13,500 pounds.

3.3.7 Stability and safety. The LCRTF shall conform to all applicable requirements of

ANSI/ITSDF B56.6.

3.3.8 Turning diameter. The LCRTF shall have a turning diameter, curb to curb, of no more than 30 feet as defined by SAE J695.

3.3.9 Angles of approach and departure. The LCRTF shall have an angle of approach and departure of at least 45% while carrying a rated load, in the retracted carry position (see 6.5.3).

3.3.10 Longitudinal gradeability. The LCRTF shall be capable of ascending a 45% grade in forward gear range at a speed of not less than 1.5 miles per hour (mi/hr), on a dry concrete surface free from loose material, with the air conditioning at full cool setting, and all lights on, with and without the rated capacity load.

3.3.11 Dynamic side slope stability. The LCRTF shall be capable of negotiating 30% grade side slopes in a full circle operation on dry concrete free from loose material on slopes, with and without rated load.

3.3.12 Braking. The service brakes shall meet all the requirements of ITSDF B56.6, and capable of restraining the vehicle on a 30% slope while carrying a rated load. The LCRTF shall have a parking brake meeting the requirements of ITSDF B56.6, but capable of restraining the vehicle on 30% slope while carrying a rated load.

3.3.13 Boom.

3.3.13.1 Reach and capacity. The extendible boom of the LCRTF shall have a minimum forward reach of 110 inches. It shall have a minimum boom lift angle of 60° and minimum lift height of 140 inches. The minimum payload at 140 inches lift height shall be 500 pounds and minimum pick load at 110 inches forward reach shall be 1,750 pounds.

3.3.13.2 Boom controls. Boom lift and lower and boom extension and retraction shall be accomplished both simultaneously and independently.

3.3.13.3 Detachable carriage. The LCRTF shall have standard quick attach and detach couplings for each hydraulic circuit required for operation of attachments (such as different size fork carriages, or other attachments for other mission roles), to minimize hydraulic fluid leakage or entrance of air into the hydraulic system. The mechanism for attaching and releasing the carriage itself can be fully manual using no tools, or onboard tools only, or can have a hydraulic assist. It is not expected that the carriage will be changed frequently.

3.3.13.4 Lowering Speed. The boom lowering speed with the rated load from the maximum prescribed height, for a fully retracted boom, to ground level, shall be not more than 120 feet per minute at maximum governed engine speed with the control valve in the full open position. The lowering speed, measured under the same conditions without load, shall be not less than 60 feet per minute.

3.3.13.5 Emergency boom lowering and retracting. The LCRTF shall have emergency capability for the operator to lower the load to the ground without engine power or during hydraulic failure. The activation of this capability shall exist above the fording line and shall be conducted without any additional assistance or special tools, or without rerouting of the hydraulic system lines or hoses. This action shall not result in spilled hydraulic fluid. During emergency lowering, fork leveling shall be maintained and the load must be lowered in a controlled safe manner, not exceeding the maximum lowering speed. This action shall not result in spilled hydraulic fluid. The boom shall be capable of being retracted and lowered so that the load may be removed in preparation for transportation. Any equipment that may be needed to perform the boom lowering and retraction shall be included with the vehicle, and added to the Basic Issue Items (BII), and stored in the BII storage box (see 3.3.41).

3.3.14 Carriage control. The LCRTF carriage shall have hydraulically controlled side shift, fork spread, fork tilt, and oscillation operated from the seat in the cab, to perform all load handling. The fork tilt angle shall be automatically maintained at level or its initial angle throughout the lifting and lowering cycle, allowing not more than 2 degree tilt back or 2 degree tilt forward when the forks are lifted from ground level at maximum lift speed to maximum boom angle, and lowered from maximum boom angle to ground level, at maximum lowering speed with the boom fully retracted. Hydraulically powered oscillation of the fork carriage about the vehicle longitudinal centerline may be accomplished via tilting of the forklift chassis. The forklift shall be capable of oscillating rated load at each maximum side shifted position. The oscillation of the rated load from horizontal shall be not less than 10 degrees clockwise when the load is side shifted to extreme left and not less than 10 degrees counterclockwise when the load is side shifted to extreme right (20 degrees total oscillation).

Time to oscillate the total 20 degrees shall be not more than 7 seconds at low engine idle and not less than 3 seconds at high engine idle for both clockwise and counterclockwise rotation.

The carriage must be capable of at least 10 degrees forward and 20 degrees rearward fork tilt under all conditions. Fork tines shall have a minimum length of 42 inches and designed for a 24-inch load center. The fork tips shall be visible to the operator with the forks level and on the ground, the boom fully retracted, and the carriage and forks in standard position and centered about the machine centerline.

3.3.15 Operations.

3.3.15.1 ISO container operations. The LCRTF shall be able to load and remove standard pallets (40 inches wide, 48 inches deep and 41 inches high), from the 40-inch end, side by side inside an 8 foot tall, 20 or 40 foot long ISO container, without manual adjustments to the fork tines.

The LCRTF shall be able to load and remove standard pallets (40 inches wide, 48 inches deep and 41 inches high), stacked 2 high, from the 40-inch end, side by side inside an 8.5 foot tall, 20 or 40 foot long ISO container, without manual adjustments to the fork tines. The LCRTF shall meet the requirements of this paragraph with containers having the minimum internal dimensions and door opening dimensions for freight containers as specified in ISO 668.

3.3.15.1.1 Backrest extension. The pallets can be of different heights, therefore a removable load backrest extension may be used to supplement the fixed backrest, if needed to increase the load restraining area. The removable backrest extension shall be removed if necessary to handle a short pallet placed on top of a tall pallet inside a container. The backrest extension shall be removable by one person without tools or with onboard tools only. Stowage provisions for the load backrest extension are not required. The backrest extension shall not exceed 37 lbs in accordance with MIL-

STD-1472.

3.3.15.2 Productivity. The productivity shall be at least 80% of the below stated productivity, while wearing arctic clothing and MOPP IV. The following items (one each) are the NBC and Cold Weather Clothing.

a. NBC protective ensemble:

(1) Chemical-biological mask, NSN 4240-00-926-4200.

(2) Chemical-biological hood, NSN 4240-00-999-0420.

(3) Chemical protective suit, NSN 8415-00-407-1062.

(4) Chemical protective glove set, NSN 8415-01-033-3519.

(5) Chemical protective footwear, NSN 8430-01-021-5978.

b. Extended cold weather clothing system:

(1) Parka, Extended Cold Weather Camouflage, NSN 8415-01-228-1306

(2) Mitten Set, Extreme Cold Weather, NSN 8415-00-782-6715

(3) Hood, Balaclava, Extended Cold Weather, NSN 8415-01-310-0606

(4) Boot, Extreme Cold Weather, Insulated White, NSN 8430-00-655-5548

3.3.15.2.1 Container unloading/loading productivity. The LCRTF, with a trained operator, shall be able to move 16 standard pallets (40 inches wide, 48 inches deep and 41 inches high) from a loaded 8.5 foot by 20 foot ISO container, on the ground, into an empty 8.5 foot by 20 foot ISO container, on the ground, with an average cycle time not to exceed 5 minutes per pallet.

The LCRTF shall meet the requirements of this paragraph with containers having the minimum internal dimensions and door opening dimensions for 1CC freight containers as specified in ISO

668. There is no productivity requirement for 8 foot container operations.

3.3.15.2.2 Load placement productivity. The LCRTF, with a trained operator, shall be able to meet the Army’s minimum average productivity cycle time of 5 minutes/pallet during load handling operations over test courses described in test method no. 7 (see appendix G).

3.3.15.2.3 Durability. The LCRTF shall complete 200 hours of operation on the durability course as specified in 4.3.15.2.3 without a durability failure and without exceeding specified temperature limits for the cooling system, engine oil, transmission fluid, differential grease, or hydraulic oil.

3.3.15.2.4 Terrain requirements for container unloading/loading and load placement. The productivity requirements in paragraph 3.3.15.2.1 and 3.3.15.2.2 must be met while operating on improved terrain 30%, and on natural terrain 70% of the time. The terrain is categorized by the roughness of the course measured in root mean square (rms), by a profilometer prior to and during test operations on the respective course in accordance with TOP 1-1-010.

Improved Terrain is defined as a hard surface and/or gravel area. The RMS value will be less than 0.3 inches.

Natural terrain will be replicated by a combination of unimproved and cross country terrain.

Unimproved terrain will be an area which has been leveled with large obstacles removed, and cross-country to be an area in which no excavation has been done. Conditions of the terrain may include snow, mud, and desert and beach sand. The course will be graded to an initial RMS roughness between 0.3 and 0.5 inches. This terrain profile will be maintained for the Load Placement Course, but does not need to be maintained for the Container Loading/Unloading Course.

3.3.16 Fuel tank capacity. The LCRTF shall have a fuel tank capacity that provides for 10 hours of continuous operation using any of the fuels listed in 3.3.22. The duty cycle is described in table IV.

3.3.17 Lights. Work lights shall be provided. A minimum requirement of one overhead light shall be mounted on the front and one on the rear. They shall be adjustable and located to illuminate maximum work area. The work lights shall not be the highest point on the vehicle.

These lights shall be protected from likely damage or breakage.

3.3.18 Load capacity indicators.

3.3.18.1 Load chart. The LCRTF shall be provided with a clearly legible chart, visible to the operator in his operating position, giving load handling capacities in conformance with the ITSDF B56.6 requirements for capacity, rated capacity, and nameplates and markings (see 6.5.5)

3.3.18.2 Longitudinal Load Moment Indicator (LLMI). The LCRTF shall include a

LLMI to alert the operator of a possible overload or instability problems with a visual display and an audible alarm. In the event of an overload or instability condition, the LLMI shall disable the boom extension handling function of the forklift until the load is brought within rated capacity limits. The LLMI shall be compliant with BS EN 15000, Safety of industrial trucks - Self propelled variable reach trucks - Specification, performance and test requirements for longitudinal load moment indicators and longitudinal load moment limiters.

3.3.19 Reserved.

3.3.20 Environmental. Asbestos, beryllium, Class I and Class II Ozone Depleting

Substances (ODS), hexavalent chromium, cadmium, mercury, lead, radioactive materials, and other Group 1 Agents classified as "carcinogenic to humans" by the International Agency for Research on Cancer (IARC) Monographs shall not be present in or on any delivered materials, required for the operation and sustainment of the system, or used in final system manufacture and assembly processes. See the SOW for additional information.

The following materials may be used without prior approval from the Government:

a. Cadmium on electrical connectors and back shells used to mate with cadmium electrical connectors on Government Furnished Equipment (GFE)

b. Chemical Agent Resistant Coating (CARC) primers and topcoats

c. Lead-acid batteries

d. Lead solder

e. Steel containing up to 0.35 % lead by weight

f. Aluminum containing up to 0.4 % lead by weight

g. Copper and Brass alloys containing up to 4 % lead by weight

h. Beryllium and Beryllium alloys used in electrical components

i. Nickel and Nickel alloys used in electrical components

j. Mercury containing components compliant with European Union (EU) Directive

2002/95/EC (RoHS)

k. Trace amounts of identified restricted materials contained in base materials and/or alloys. For the purposes of this contract trace amounts are defined as <0.1% by weight for carcinogens and <1%by weight for all other materials.

3.3.21 Symbols. All operator vehicle and load handling controls shall be labeled and shall conform to ISO 3287.

3.3.22 Fuel and emissions. The LCRTF, while operating on approved fuels (see below) shall meet the requirements specified herein.

a. Approved fuels: In order of priority the following approved operational fuels are:

JP-8 meeting MIL-DTL-83133 (F-24, Jet A meeting ASTM 1655 with full military additive, shall be used instead of JP-8 in CONUS at temperatures above -40C); JP-5 meeting MIL-DTL-5624;

Jet A meeting ASTM 1655 with corrosion inhibitor/lubricity improver (CI/LI) meeting Mil-PRF- 25017, Jet A-1 meeting ASTM 1655 with CI/LI meeting Mil-PRF-25017, and diesel fuel meeting

ASTM D975

b. F-24 is Jet A meeting ASTM D 1655 with full military additive package - static dissipator (SDA) as indicated in JP-8, fuel system icing inhibitor (FSII) meeting MIL-DTL-85470, and CI/LI meeting Mil-PRF-25017. This fuel is primary fuel for (CONUS) operations.

3.3.22.1 Non-Armored, Non-road Equipment Engine Exhaust Emissions: The engine provided shall be of the latest engine technology that will meet all the performance requirements specified in this PD while operating on fuels listed in this section, which may have up to 3,000 ppm sulfur, and military lubricants (see 3.2.23). The engine supplied shall be compliant with EPA Tier III non-road exhaust emission standards. Pollution control technologies that are impacted by the sulfur level of the JP-8 fuel either in maintenance or life expectancy shall not be used, e.g., externally cooled Exhaust Gas Recirculation (EGR), NOX traps, catalytic converters, etc. In addition, lubricity canisters or filters shall not be required for proper engine operations (O). Contractor shall ensure National Security Exemption labeling requirements are met IAW EPA regulations. See further directions in the Scope of Work (SOW).

3.3.22.2 Reserved.

3.3.23 Lubricants and Fittings. A lubrication means shall be provided for all moving parts requiring lubrication. The LCRTF and all components within shall be compatible with military lubricants and fluids. A list of military lubricants can be found in the TARDEC POL Products Guide dated January 2012. Army systems have standardized on the following main products: MIL PRF 2104 (standard engine oil), MIL-PRF-32073 (biodegradable hydraulic fluid), Mil-PRF-46170 (fire resistant hydraulic fluid), SAE J2360 (gear lubricant), MIL PRF 46167 (Arctic Engine oil), SAE AMS M 7866 (Molybdenum Disulfide, Technical, Lubrication Grade), MIL PRF 10924 (grease), and MIL PRF 46176 (silicone brake fluid). In conformance with AR- 70-12, minimizing the number of POL products required to maintain the system shall be considered for Army applications to the greatest extent possible. Lubrication fittings IAW SAE J534 shall be located in a protected, accessible location. Fittings shall be accessible to a grease gun with a 10 inch flexible extension. Extended lubrication points shall be used for hard to reach areas. A lubrication data plate shall be provided (attached by screws, bolts, or rivets in a conspicuous protected location) and conform to SAE J753. The plate shall identify military lubricants and all lubrication points. Fluid drain points shall include a ¼ turn ball valve and an extension hose, as needed, to allow full or partial drainage directly into a container to avoid environmental oil spills regardless of the orientation of the vehicle or tires.

3.3.24 Operating environment requirements.

3.3.24.1 Operating environment conditions. The LCRTF shall be able to operate during all types of climatic, weather, and illumination conditions, including blowing sand and dust particles, without performance degradation. In order to minimize water trapped in the engine compartment, access panels, cab or cab door, or exhaust system, SAE J447, Prevention of corrosion of motor vehicle body and chassis components, shall be used as design guidance in order for the vehicle to shed water during static and dynamic vehicle operations.

3.3.24.2 Operating and storage temperatures. The LCRTF shall operate in the temperature range of -25 to 120 °F and sustain storage temperatures of -40 to 140 °F.

3.3.25 Reliability. The LCRTF shall demonstrate a Mean Time Between Essential Function Failure (MTBEFF) of 120 hours. Essential functions of the forklift are to move and lift cargo up to its rated load capacity. Events that prevent the LCRFT from performing an essential function, such as those events posing threat of serious injury to personnel or equipment, are also considered EFFs.

External leakage, as defined in SAE J1176, for the systems listed below, will be scored as EFFs:

SAE Class 0 or Greater SAE Class 3 or Greater SAE Class 4 or Greater

Fuel system Coolant Hydraulic system Hydraulic brake system (except brake system)

Transfer case Axles Engine Transmission All remaining systems

Events that do not affect or interrupt the essential functions are not considered to be EFFs. For example, nonrepetitive replacement of light bulbs will not be considered an EFF. Routine operating procedures, performed by the crew and prescribed in user manuals or which can be performed within 30 minutes using on board tools (BII), will not be scored as an EFF.

Examples of routine operating procedures are tightening of easily accessible fittings, clamps, bolts and fasteners.

3.3.26 Maintainability. Provisions shall be made for servicing and replacement of all parts and components using only the Army General Mechanics Tool Kit, Automotive, NSN 5180-01-548-7634, and Standard Automotive Tool Set, NSN 4910-01-531-2053, authorized at field level maintenance. In order to facilitate the removal of major drive train components (such as the engine) in the field, the entire engine bay covering shall include provisions to attach a lifting sling from the Standard Automotive Tool Set. The lifting provisions shall be a permanent part of the engine bay cover, and shall not require the use of tools to attach the lifting sling. Any engine bay covering component(s) weighing more than 500 pounds shall have lifting provisions compliant with MIL-STD-209. All access openings shall be in compliance with commercial practices and SAE J185. The following maintainability standards must be demonstrated:

3.3.26.1 Median Time To Repair (MedTTR). MedTTR for all Essential Unscheduled maintenance Demands (EUMD) shall not exceed 1 hour.

3.3.26.2 Maximum Time To Repair. Maximum Time To Repair for 90% (MAXTTR 90) of all EUMD shall not exceed 2 hours.

3.3.26.3 Maintenance Ratio (MR). Total MR shall not exceed 0.046 maintenance manhours per operating hour.

3.3.26.4 Preventive Maintenance Checks and Services (PMCS). The LCRTF shall include a daily operator functional inspection developed by the manufacturer, to be performed by the operator through the use of well defined check-lists or similar performance standards, that takes no more than 20 minutes. Preventive maintenance (PM) involving the systematic inspection of the LCRTF to ensure its continued readiness prior to operation shall be performed weekly in a mean time of less than 2 hours. PM shall include the use of PM check-lists. These shall address such procedures for obtaining access to subassemblies and sub-components, and inspection procedures for parts that deteriorate due to cycles of use, age, or climatic conditions.

3.3.27 Human factors engineering. The LCRTF shall be operable, maintainable, repairable, and supportable by the smallest (5th percentile female) through the largest (95th percentile male), as defined by MIL-STD-1472, qualified personnel while wearing the full range of clothing, including body armor, arctic and MOPP IV. Noise generated by the forklift shall conform to the requirements stated in MIL-STD-1474. Should the forklift exceed allotted noise levels, a warning label shall be visible for the need for hearing protection. The forklift shall not exceed the limits for single hearing protection.

3.3.27.1 Emergency egress. The LCRTF cab shall provide a means for an emergency egress through the front windshield or boom side window. The minimum size of at least one of the emergency egress windows shall be 26" x 30" (height x width) to meet the requirements of MIL- STD-1472. The LCRTF shall provide a secondary means for emergency egress through the rear window when operating within an ISO Container. The rear emergency egress shall be 13" x 25" (height x width) Threshold and 26" x 30" (height x width) Objective. Hot surfaces, such as exhaust system components, shall be routed or shielded to prevent burns during emergency egress operations.

3.3.28 Travel speed. The maximum travel speed of the LCRTF for self-deployment, shall be a minimum of 20 mi/hr, without load, on improved roads for a distance of 30 miles. The LCRTF, with a rated load, shall travel for distances up to 3 miles over unimproved surfaces, at a forward speed of at least 10 mi/hr. The LCRTF operating temperatures and pressures shall remain within the normal recommended ranges. Travel speed requirements shall be met with the air conditioner operating at full cool setting.

3.3.29 Fording. The LCRTF shall be capable of operation without degradation of functions in water to a minimum depth of 12 inches (T); 36 inches (O), without use of fording aids. A fording aid is any device or treatment or application of materials to the vehicle prior to fording. Fording environmental variables include variations in water (e.g. fresh water, floating ice water, muddy swamp water, ocean-brackish salt water mixed with beach sand). Fording times in all types of water will vary from one minute to a maximum continuous submersion of 5 minutes. Total submersion time per 12 hour shift will not exceed 1.5 hours (per OMS/MP Movement w/in site) during Logistics Over the Shore Operations.

3.3.30 Towing. The LCRTF shall be capable of being safely towed, with a dead engine, behind a M-1078A1 Family of Medium Tactical Vehicles (FMTV) 2.5-ton truck (NSN 2320 01 447-6343) and M-1083A1 FMTV 5-ton truck (NSN 2320-01-447-3890) (see 6.5.11), on improved roads at speeds of at least 12 mi/hr (T); 35 mi/hr (O), for not less than 30 miles, without damage to the LCRTF or Towing Vehicle. The driveline may be provided with a means to disengage the wheels from the transmission for towing, if needed to meet this requirement. A towbar shall be furnished, hinged at two points on the forklift, and with a solid towbar eye in accordance with SAE J847. A lockup latch shall be provided to secure the towbar in an upright position when not in use. Two safety chains, equipped with safety type grab hooks, shall be furnished; and each chain shall be of an ultimate strength equal to or greater than the weight of the forklift. The LCRTF shall be prepared for towing by no more than 4 soldiers, in not more than 45 minutes, in 90 degree F temperatures, or lower, using only the vehicle onboard tools included with the BII (see 3.3.41), or no tools. The reverse shall also be accomplished in not more than 45 minutes under the same conditions.

3.3.31 Slinging and tie-down provisions.

3.3.31.1 Slinging provisions. Sling provisions shall be provided. The LCRTF shall be capable of being lifted by a CH-47 helicopter, using standard Army 25,000 lb. sling load slings (NSN 1670-01-027-2900) in both single point and dual point mode, and be compliant with MIL- STD-913 and MIL-STD-209. The use of spreader bars is not permitted. Slinging provisions may also be used as tie-down provisions when appropriate.

3.3.31.2 Tie-down provisions. Tie-down provisions shall be provided for transportability by air, rail, commercial carrier, Maritime Prepositioning Shipping, commercial shipping, and the Army organic motor transport assets. This includes transportation by Palletized Load System (PLS) or the Heavy Expanded Mobility Tactical Truck Load Handling System (HEMMT LHS), using the M1077/M1077A1 flatrack, NSN 3990-01-307-7676, U.S.

Army Tank-Automotive Command Drawing Number 87T0013, M3 flat rack, NSN 3990-01- 442-2751, and M3A1 flatrack, NSN 3990-01-450-5671, U.S. Army Tank-Automotive Command Drawing Number 1246870. The flatracks listed are limited to 40 PSI actual deck pressure measured at the tire treads. If shoring is required to achieve less than 40 PSI, a shoring design shall be included in the transportability report for review and approval by the Government prior to PVT vehicle delivery. See Paragraph 6.8.1 for additional information. The angles that the vehicle will be subjected to, in automatic mode, are 35 degrees for the flatrack used with a PLS and 19 degrees for the flatrack used with the HEMTT LHS. Transportation via flatrack will be in highway and off-road modes only, not to include rail, maritime or air. The forklift shall have four tie-down provisions conforming to the strength requirements of MIL-STD-209. When loaded on a rail car, the forklift shall withstand the shock loads resulting from rail impact testing in accordance with MIL-STD-810, Method 526 without failure, damage or permanent deformation. The LCRTF shall meet the requirements for transportation aboard C-17, C-130, and C-5 air transport, per MIL-STD-1366. The forklift shall be capable of being driven on and off all aircraft in fully operational configuration.

3.3.31.3 Preparation for sling lift. Exposed boom hydraulic tubes or hoses that may be subject to possible damage during preparation for sling lift shall be protected from damage. This protection is only required to support the weight of personnel as defined in 3.3.27.

3.3.31.4 Low Velocity Air Drop (LVAD). The LCRTF shall be capable of being airdropped from C-130 aircraft without breakage or permanent deformation of any structural member or component, or loss of the LCRTFs ability to perform all functions specified herein.

The LCRTF shall be transportable while filled to 75 percent fuel capacity. MIL-HDBK-669 can be used as a guide for determining impact forces resulting from airdrop. Although not a requirement of this document, the government will rig and drop in accordance to the design requirements defined in MIL-HDBK-669. If additional tie down provisions are needed to rig for air drop, these can be a permanent part of the vehicle or can be a bolt on air drop kit or combination of the two. The additional weight of the bolt on kit does not count towards the 13,500 pound vehicle curb weight limit. The bolt on kit is not required to be stored on the vehicle.

3.3.31.5 LVAD Parachute suspension provisions. Four integral suspension provisions conforming to MIL-STD-814 shall be furnished on the LCRTF. The parachute suspension provisions shall withstand the stresses in the amount and direction of pull specified without weld failure or permanent deformation of the LCRTF or the provisions. The parachute suspension provisions shall be labeled “ATTACH DROP PARACHUTE HERE” in 0.5 inch letters.

3.3.32 24 VDC electrical system.

3.3.32.1 Battery and electrical system. The LCRTF shall be equipped with a 24-volt negative-ground electrical system or at a minimum have a 12/24 dual system with a 24 volt alternator, 24 volt starter and a charge equalizer (battery equalizer). The batteries shall be the Absorption Glass Mat (AGM) type meeting the requirements of MIL-PRF-32143. Electrical wiring shall be in accordance with SAE J1614. A master switch shall be provided that disconnects the batteries from the electrical system thus preventing accidental draining of the batteries when the vehicle is not in use. The switch shall be located above the fording line, accessible and conveniently located for operation.

3.3.32.2 Slave receptacle. The LCRTF shall be equipped with a 24-volt slave receptacle conforming to NATO STANAG 4074, Type 1. The slave receptacle shall permit charging of the batteries and slave starting of the engine from an external power source and shall also provide a power source for charging and slaving other equipment. The receptacle shall be installed on the exterior of the forklift near the battery enclosure, above the fording line, and shall be accessible to personnel standing on the ground. The receptacle shall be labeled "SLAVE 24 VOLTS DC" with one-inch black lettering.

3.3.33 Blackout lighting. The LCRTF shall be furnished with one head and two tail and stop blackout lights conforming to MIL-STD-1179. An interior switch conforming to MIL-PRF-11021 (mechanical type), which is readily accessible to the operator in the seated position, shall control the blackout lights. All other exterior lights, backup alarm and the horn, if electric, shall be made inoperable automatically when the blackout lights are switched on. All exterior lights, front and rear, backup alarm and horn shall be protected from likely damage or breakage. The blackout mode switch shall activate all blackout lights and markers.

3.3.34 Chemical Agent Resistant Coating (CARC). The LCRTF shall be cleaned, pretreated, primed and topcoated in accordance with TACOM drawing number 12585018, Chemical Agent Resistant Coating System for Exterior and Interior Army Materiel. MIL-DTL- 53084 electrocoat shall be used where practical with MIL-DTL-53039 topcoat. High hard steel or surfaces with a peak surface profile greater than 23 μm (0.9 mils), shall be cleaned, pretreated, primed and topcoated with CARC in accordance with material preparation TT-C-490 Method I, Zinc-Rich Coating: TT-C-490 Type VIII IAW A-A-59745, Topcoat: MIL-DTL-53039 and MIL- DTL-53072. Unless otherwise specified in the delivery order, the topcoat color shall be tan 686A, #33446 of FED-STD-595. Camouflage pattern is not a requirement. The manufacturer shall select a Chemical Agent Resistant Coating (CARC) system that achieves at least 1000 hours protection in ASTM B117 salt spray testing, and offers reduced emissions of Volatile Organic Compounds (VOCs). Surfaces not normally painted shall be treated against corrosion or shall be fabricated of materials that are inherently corrosion resistant. Hydraulic cylinder rods and seals shall not be painted. Coatings shall be selected to provide maximum life of corrosion resistance and that are resistant to environmental degradation and coating chipping. Components not visible or exposed during normal operation may be painted with the manufacturer’s commercial paint and color. High temperature surfaces such as exhaust stacks and manifolds shall not be topcoated with CARC, but rather high temperature paint of limited reflectivity. The color shall be consistent with specified vehicle topcoat requirements, i.e. tan 686 or manufacturer’s commercial color. Surfaces not suitable for painting shall be treated to, or inherently provide, a surface of limited reflectivity. Mating surfaces of structural components, toinclude wear pads, shall not be topcoated.

Prior to the delivery of FAT/PVT systems, the contractor shall show conformance to the CARC process as outlined in MIL-DTL-53072 by performing the test outlined in section 4.3.34 and provide the government a conforming test report with additional coupons for independent government testing.

3.3.35 Nuclear, Biological & Chemical (NBC) contamination survivability. To meet the Nuclear, Biological and Chemical (NBC) survivability requirements, materials shall be selected which can be decontaminated, without degradation, when cleaned. The LCRTF shall be capable of being decontaminated using standard and non-standard decontaminants listed in FM 3-11.5, with the exception of DS2 and super tropical bleach, without significant degradation. The LCRTF (with the exception of hydraulic hoses, tires, and rubber components) shall be able to withstand the materiel damaging effects of NBC contaminants and decontaminants, without performance degradation, and be decontaminable to negligible risk levels to reduce hazard to personnel operating and maintaining the system.

3.3.36 Pintle. The pintle hooks shall conform to A-A-52550.

3.3.36.1 Rear Mounted Tow Pintle. A rear mounted pintle hook shall be provided for towing other equipment between worksites. The terrain would be unimproved (see 6.5.8.2). The rear pintle hook shall be located on the vertical centerline of the forklift, not less than 31 inches nor more than 37 inches above ground level. The pintle hook mounting shall be of sufficient strength to withstand, without permanent deformation or damage, the drawbar pull induced when the pintle hook is restraining forward motion at vehicle stall, with full throttle applied, and when used in normal operations.

3.3.36.