Attachment 0032 - Overpaint Criteria.doc

ATTACHMENT 0032

FMTV OVERPAINT CRITERIA

06 September 2002

This document will serve as the basis of direction and guidance for preparation and completion of all FMTV vehicles, which require overpaint. Overpaint is the application of a different paint color/scheme on top of an already painted vehicle. The possible overpaint situations would be that of a green 3-color camo painted vehicle converted to a solid tan/sand colored vehicle and vice-versa.

The contents of this document are directed at vehicles already assembled. Where the words Assemble, Disassembly, Interference, Partial coverage, Direct coverage, Overpaint. Outboard Surface, Inside Surface Top, Bottom and Installed are inserted into this text they apply to already assembled vehicles and may or may not apply to new build vehicles.

The intent of this document is to provide guidance and direction to produce a vehicle that appears completely green 3‑color camo/tan/sand from a distance of 15 feet in a standing position, without magnification or use of a flashlight. There are no exceptions to the 15-foot distance requirements. Inspections begin and remain at the 15-foot distance. They do not start at less than and end at 15 feet. Inspections occur at 15 feet from ground level and up, i.e., not with the vehicle to be viewed on an elevated plane. Operators will paint everything within reasonable access inside the current paint booths without crawling under the vehicle or performing any other unsafe act. They will not place themselves into any unsafe position not normally performed inside these booths. This overpaint standard allows for less than Direct paint coverage of green 3‑color camo/tan/sand paint on hidden components and shaded areas where space limitation inside the paint booth prevents access or use of approved painting techniques. All vehicles to be overpainted will be masked and taped as required to meet the requirements outlined in this document.

The following are groupings of components or areas that will clarify paint requirements in specific areas. They are:

1) Areas of direct paint coverage required,

2) Areas where less than direct. spray coverage is acceptable,

3) Areas where no green 383 3‑color camo/tan/sand painting is required,

4) Areas where overpaint is allowed,

5) Miscellaneous additional comments,

6) Additional requirements for the wrecker,

7) Additional requirements for the MHE,

8) Additional requirements for the tractor,

9) Additional requirements for the van, and

10) Additional requirements for the dump.

Definition of Paint Terms

Note: Definitions of paint terms are listed below.

Paint and Painted is to intentionally apply a coating of green 3‑color camo/tan/sand paint on the exposed surface of a vehicle or its components to the extent that it 'appears' to be green 3‑color camo/tan/sand.

Direct Paint Coverage is intentional 'paint' as defined above that is required on surfaces of specific components where the exposed areas of those surfaces are normally visible when viewed as defined in this criteria.

Less than Direct Spray Coverage is intended paint coverage but limits the amount or area covered to allow for interference of other components or would if directly coated interfere with the intended function of the component. It may also be the result of safety factors or space limitations inside of the paint booth. It is an accepted end result where identified in this criteria.

Minor Overspray is unintended light: coating of spray paint on certain components not normally painted but may exhibit signs of overspray if not specifically masked or protected. Minor overspray is expected on chose areas where listed in this criteria and is acceptable.

1~ Direct Paint Coverage

Direct paint coverage is required on areas that are visible without magnification or flashlight when looking directly at the vehicle from the front, sides, rear or top from a minimum of 15 feet. This inspection will be from a standing or kneeling position. Direct coverage is required on surfaces of specific components, where the areas of those surfaces are normally visible when the vehicle is viewed directly from the front, sides, rear or top, as listed below, with limitations.

Cab and doors (exterior only), excluding lower portions of the rear of cab.

Cargo body top surface and sides. May be inspected with use of an automotive stand. (See limitations below)

Tailgate and side panels to be overpainted in up and down position inside of paint booth. (To include outer edges of tailgate.)

Troop seats with straps to be in stowed position. Straps to be removed and *racing stripe' will be hand painted or sprayed.

· Mirror arms and mirrors will be removed from vehicle and painted to achieve acceptable coverage (mirror glass surface to be masked).

· Cargo stakes will be painted while in the installed positions.

· Cargo body ladders will be removed from the vehicle and painted to achieve acceptable coverage.

Outboard surfaces when viewed from eye level of vehicle and 360 degrees (standing walkaround). These items require no green 3‑color camo/tan/sand painting on any inside surface and will be painted on vehicle as installed. Areas normally hidden from view will not require any green 3‑color camo/tan/sand over‑paint.

Toolbox(s).

Wheel rims ‑ black.

Bumper, direct spray outboard front only. No inside requirement.

Front grille, Outboard surface only.

Sub rails. Outboard surface, as access in paint booth will permit.

Fuel tank (to include rock shield) outboard surface. as mounted.

Cargo body Tie‑downs rings, excluding bottom side outboard top surface as mounted (to include rockshield).

Frame rails, outboard only with attachments installed. as limited by paint booth.

Air intake with the exception of the top black cap.

Air tanks (to include rock shield) as mounted, outboard exposed surface only.

Spare tire carrier (to meet walkaround criteria) will be limited to accessible areas in paint booth.

Battery box cover as installed) outboard only. (Also, see section 8 tractor limitations.)

Hydraulic tank as mounted, outboard surface only.

Towing shackles (will be re‑routed through small parts, paint).

Rear tension beam located at rear of vehicle between main rails, viewed just above the gladhands on rear crossmembers outboard surface only.

Spare tire wheel rims to be removed from the vehicle and painted to achieve acceptable coverage on rim.

2.

Areas Where Less Than Direct Coverage is Acceptable

These areas, although less than direct coverage. will appear to be completely painted from a distance of 15 feet minimum from a standing or kneeling position without magnification or flashlight.

Wheel rim hardware including wheel rims studs, nuts and hub assembly (total coverage not possible in booth).

Sides of reflectors, as seen from 15 foot minimum.

Front/rear of mudguard braces (overpaint acceptable on mud flap).

Shock absorbers outboard top only.

Drive shafts, light overpaint only, total coverage not possible in booth.

Front/rear springs will have light overpaint only.

CTIS wheel components Outboard surface only as limited by paint booth access.

Crossmembers, no attempt will be made to paint front and center crossmembers.

Intermediate axle, slight overpaint as access will permit, as viewed from 15 feet.

Cargo body, top surface, sides, underside from outer edge to frame

Front axle as limited by paint booth, as viewed from 15 feet (slight overpaint as access will permit).

Rear axle as limited by Paint booth. as viewed from 15 feet (slight overpaint as access will permit). Composite light housings (outboard surfaces only) slight overpaint possible.

Blackout light housings same as composite, as viewed from 15 feet.

Rear crossmember, backside and bottom only, as viewed from 15 feet.

Rear tension beam, exposed surface from rear view only.

Under ride guard, exposed surface, rear and side view only.

Winch kit, drum and brackets outboard surfaces only with light overspray on exposed cable.

Pintle hook, outboard surface on hook itself, no paint on support.

Ladder stowage area to be overpainted as far as it can be reached. as limited by paint booth.

Rear of cab lower portion.

Troop seat alarm assembly will be painted in the installed position.

3.

Areas requiring no Green 3-color Camo/tan/sand Paint

These areas are normally hidden from view and will require no green/3‑color camo/tan/sand color.

Underside of cargo inside of the area between frame rails and on the forward side of the bulkhead including inside of panel stowage areas.

Brackets mounted to the engine, trans., etc. (No engine overpaint).

Inside of frame rails and sub rails.

Components within frame rails (inside).

Interior of cab, interior of tool box(s), accessory box (steps) (to include areas covered by lip and door lids) and inside of battery and stowage boxes.

Hidden surfaces of bumper i.e., inside surfaces.

Hidden surfaces of main and sub rails.

Engine compartment to include tunnel

Door jambs.

Surfaces of the heli‑lift bars not visible in the retracted position.

Inside of air transport control box or any other box or compartment.

Cooling fins of the air dryer, auxiliary oil cooler fins, radiator fins

Front fenders to include step tread.

Any other part or surface not accessible inside paint booth.

Quick start cylinder to remain orange (safety warning issue).

Inner surfaces of rear light brackets.

4.

Areas Where Minor Overspray is Allowed

As a result of painting fully assembled vehicles. certain components not normally painted, will be expected to exhibit signs of overspray. Specific examples are, but not limited to:

· Sidewalls of the tires.

· Wiring harness.

· Air lines and fittings

· Hydraulic lines and fittings

· Rubber bump stops and rubber suspension components.

· Winch cables.

· window seals and door seals, mirror seals

· Front/rear of mudguard.

· Lube surfaces.

· Glass and plastic surfaces including lenses and reflectors

· Dataplates and identification decals

· Quickstart cylinder.

S.

Miscellaneous Additional Comments

BII/OVE will be removed before painting and the components will remain green. Acetylene tanks will not be removed or painted.

Windshield wiper arms and blades will be removed and will remain black.

No data, instruction or warning plates will be changed.

Black spare tire carrier strap will remain as is. Overspray allowed.

Splash shield for auxiliary cooler not to be painted (minor overpainting allowed)

Any stencils over‑painted will be restenciled, if the paint renders it unreadable.

Surge tank to be overpainted as mounted.

Exhaust pipe to remain black with its heat resistance paint.

Weight class sign to remain on vehicle, the mount and hardware will be overpainted. (Note: Numbers will not be painted.)

Engine area will not be overpainted.

6.

Additional Requirements for the Wrecker

Amber warning light mast must be removed and overpainted.

Auxiliary oil cooler frame (top and sides) to be green overpainted. Fins to remain black.

Wrecker control panel to be replaced with a green 3‑color camo version.

Wrecker control panel handles will be green 3‑color camo overpainted. (Note: Knobs will not be painted.)

MHE crane control panel to receive less than direct overpaint coverage. Knobs to be masked so as not to receive any paint.

Outriggers, MHE, lift and tow device to receive less than direct spray coverage and hand paint coverage when extended within limitation of paint booth.

Fold‑up ladders to be painted in stowed position

Lube surfaces overpaint allowed.

Stiff leg and feet to be fully extended and overpainted.

Boom rest to be fully extended and overpainted as limited by paint booth.

Wrecker bottles will not be painted.

Minor overspray on all cables (installed) is allowed.

The machine surface of all hydraulic cylinders will be free of overspray.

Stinger legs will be overpainted in stowed and extended positions.

Rear of Auxiliary cooler will not be painted (remain black) . Minor overspray allowed.

7.

Additional Requirements for Vehicles with MHE

Tailgate to be removed and overpainted.

MHE crane to be painted in the stowed position, less than direct coverage allowed.

Winch wheel partial coverage is acceptable with cable installed.

All sand shoes to be painted in stowed position. Less than direct coverage allowed.

8.

Additional Requirements for the Tractor

Less than direct coverage on the platform grating is allowed on top side. No overpaint on bottom.

Aux cooler brackets to be green 3‑color camo/tan/sand overpainted except for the fins.

Rear of the aux cooler will not be painted (remain black) . Minor overspray allowed.

Less than direct coverage on the inside of the ramps is allowed.

Direct coverage is permitted on the air lines and wiring harnesses that are located on the inside of the chassis assembly.

Pintle hook to be painted as assembled (less than direct spray coverage).

Rear tiedowns to be painted as mounted (less than direct spray coverage) .

Area directly underneath the 5th wheel will have less than direct spray coverage.

Pogo stick and attached hoses will have less than direct coverage allowed (To be painted in the installed position)

Exposed top and sides of the transmission may have overspray.

Top of the battery box will have less than direct full coverage.

Less than direct coverage is allowed on the inside of the chassis area (betweei, the frame rails) .

9~

Additional Requirements for the Van

Less than direct coverage is allowed underneath the air conditioning unit and heater unit.

Air intake will be masked to prevent overspray.

Less than direct coverage is allowed on the inside wire mesh vent area on the front panel of the van body. Less than direct coverage is allowed on the mounting surface of the intervehicular electrical hook‑up panel. Phone connectors will be masked and painted.

Main power receptacles will be painted as mounted.

Ladder to be removed and painted off‑line.

All doors will be painted in closed position.

Door keepers will be painted in the up and down positions, as mounted.

All instructional plates (identified in this proposal) will be green 3‑color camo/tan/sand painted with black stencils for the lettering. (This does not include warning and caution plates.)

Area between the rear of the cab and entire front surface area of the van box may receive less than direct coverage because of the limited access to this area when van body is mounted on the chassis.

The inside of the van box will not be painted.

10.

Additional Requirements for the Dump

Cab protector shield in the stowed (traveling) position will have less than direct coverage. Shadows expected on the inside channels.

Manual release handle will have direct coverage on the front and less than direct coverage on the back.

All tiedown rings to be painted as installed.

Dump bed to be pained as mounted.

Winch brackets and rollers to be painted as mounted. Less than direct coverage is allowed.

All instructional plates (identified in this proposal) will be green 3‑color camc, painted with black stencils for the lettering. (This does not include warning and caution plates.)

Underside of the dump bed from outer edge to frame will receive less than direct coverage.

11.

INITIAL INSPECTION FOR ALL VARIANTS

The first vehicle of all variants overpainted will be jointly inspected and agreed to by all parties concerned. The Contractor will select a vehicle and provide prior notice to all parties involved. Based upon this joint review, revisions to this criteria may result. Any impacts to costs occurring from revisions to this criteria (material and labor) could result in renegotiation of this contract mod.

12. Quality Assurance Requirements. The surfaces to be overpainted shall be inspected and cleaned in accordance with Military Specification MIL-C-53072, “CARC System Application Procedures and Quality Control Inspection”, Partagraph 3.6. The finished overpainted surface shall exhibit dry adhesion properties as specified in paragraph 4.3.3.6.1 of MIL-C-53072.

Distribution A – Unlimited; Distribution Approved for Public Release