DFP_ECB-008.pdf

DFP ECB-008

CAGE 5B5M3

10 October 2012

Rev. H

DESCRIPTION FOR PURCHASE

TOOL OUTFIT, HYDRAULIC SYSTEMS TEST AND REPAIR UNIT (HSTRU)

1 SCOPE

This specification describes a trailer-mounted hydraulic repair shop for all purpose hydraulic repair for Current and Future Forces. The outfit consists of a selection of tools and equipment suitable for support of field and sustainment maintenance of hydraulic systems. The tools and equipment are placed in rugged storage media integrated with a transportable, rapidly deployable, highly mobile, tactical trailer-mounted enclosure. To enable rapid force projection from anywhere in the world, military units need the capability to perform hydraulic hose fabrication and hydraulic system repair operations on and off the battlefield. The HSTRU provides hydraulic repair and fabrication capability for MOS 62B Construction Equipment Repairers.

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 documents cited in sections 3 and 4 of this specification, whether or not they are listed.

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be use in improving this document should be addressed to: SITE

MANAGER, RDCB-DE, Rock Island IL 61299-7300.

AMSC N/A FSC 4910

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

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) and supplement thereto, cited in the solicitation (see paragraph 6.2).

SPECIFICATIONS

FEDERAL

A-A-50271 - Plate, Identification

A-A-59487 - Padlock (Key Operated)

STANDARDS

FEDERAL

FED-STD-595 - Colors Used in Government Procurement

DEPARTMENT OF DEFENSE

MIL-STD-129 - Standard Practice for Military Marking

MIL-STD-130 - Identification and Marking of U.S. Military Property

MIL-STD-171 - Finishing of Wood and Metal Surfaces

MIL-STD-209 - Interface Standard for Lifting and Tiedown Provisions

MIL-STD-810 - Environmental Test Methods and Engineering

Guidelines

MIL-STD-913 - Requirements for the Certification of Sling Loaded

Military Equipment for External Transportation by

Department of Defense Helicopters

MIL-STD-1916 - DOD Preferred Methods for Acceptance of Product

HANDBOOKS

MIL-HDBK-784 - Guidelines – Design to Minimize Contamination and to Facilitate decontamination of Military Equipment:

Interiors and Exteriors

MIL-HDBK-1791 – Designing for Internal Aerial Delivery Handbook

PAMPHLETS

DEPARTMENT OF THE ARMY

DA PAM 40-501 - Hearing Conservation Program

(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).

2.1.2. Other Government documents, drawings and publications. The following other

Government documents, drawings, and publications form a part of this document to extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

2.2. 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. Unless otherwise specified, the issues of documents not listed in the

DoDISS are the issues of the documents cited in the solicitation (see paragraph 6.2)

ACOUSTICAL SOCIETY OF AMERICA (ASA)

ASA S1.4 - Specification for Sound Level Meters

(Application for copies should be addressed to the Acoustical Society of America

(ASA), 120 Wall Street, 32nd Floor, New York, NY 10005-3993.)

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI Z535.4 - Product Safety Signs and Labels

(Application for copies should be addressed to the American National Standards

Institute, 11 W. 42 nd

Street, New York, New York 10036.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM SI 10 - Standard for Use of the International System of Units (SI):

The Modern Metric System

ASTM D5330 - Standard Specification for Pressure-Sensitive Tape for

Packaging, Filament- Reinforced

(Application for copies should be addressed to the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, Pa 19428-2959.)

SOCIETY OF AUTOMOTIVE ENGINEERS

SAE-AS33671 - Strap, Tiedown, Electrical Components, Adjustable, Self Clinching, Plastic

(Application for copies should be addressed to SAE International, 400

Commonwealth Drive, Warrendale, PA 15096-0001)

2.3. Order of precedence. 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 Product verification. When specified, a sample shall be subjected to product verification inspection in accordance with paragraph 4.2.

3.2 Performance.

3.2.1 Tools, equipment, and supplies. Unless otherwise specified, the Government will furnish the Chassis, Trailer, Two-Wheel, NSN 2330-01-387-5424. All tools listed in

Appendix A shall be provided by the contractor. The Tool Load Listing for the HSTRU shows specific manufacturer part numbers. Contractors may propose these exact part numbers or functionally equivalents from other manufacturers. The tool load listing is considered "Brand Name or Equal". Market Research has revealed that in order to ensure a manufactured hose assembly is sufficient and safe, the crimper, hose, and hose ends must all be supplied by the same manufacturer. Thus, it is understood that a contractor's proposal shall show that the hoses, crimper, and hose ends of the various sizes specified in the tools listing all come from the same manufacturer. The contractor shall furnish the trailer-mounted enclosure, tools, equipment, storage media, electrical wiring, etc. needed to provide the performance specified herein, and integrate all tools and other items into the enclosure to provide a complete, fully-functional unit. Brackets or other restraints shall be provided on the exterior of the enclosure for the trailer stabilizer legs. A known source of supply for the tool load listed in Appendix A is Nott Company

(www.nottco.com).

3.2.2 Workbench. The enclosure furnishings shall include a workbench with a work surface not less than 30 inches wide and 16 inches deep (larger is better). The work surface shall be resilient enough to withstand impacts typical of maintenance operations without chipping, cracking, or splintering, and shall be highly resistant to damage from sun and rain. In addition to any equipment mounted on it, the workbench and its supporting structure shall be capable of supporting at least 250 pounds without suffering permanent deformation or other damage. The workbench shall have a work surface height of 39 ± 3 inches and shall be supported and stable on soft surfaces such as sand, mud, and snow. Attachment points for bench-mounted equipment shall be provided, but the bench-mounted equipment may be detachable for storage inside the enclosure during transport, in which case dedicated storage location(s) shall be provided for that purpose.

3.2.3 Vise mount. When mounted for use, the machinist’s vise shall have the full range of motion and uses anticipated by its design, including at least one position free of obstructions in the vertical plane (includes both above and below the vise) of the jaws of the vise. In addition the vise mount and its supporting members (e.g. workbench, enclosure frame, etc.) shall be rigid enough and stable enough to support the vise and work piece, and durable enough to withstand the forces exerted on the vise without sustaining permanent deformation or other damage. They shall be capable of withstanding both clockwise and counterclockwise torque of 100 foot-pounds on each of the three axes of the machinist’s vise while supporting the weight of the vise plus a 45 pound work piece.

3.2.4 Hose Crimper. The hose crimper from the tool load (KarryKrimp 2) shall be mounted in a position that allows it to be used without repositioning or shall include a mechanical assist (i.e. slides, spring or charged cylinder) to allow one soldier to position it for use. Clearance shall be provided around the hose crimper to not interfere with crimping operations. Clearance shall be provided below and to the front of the crimper to not interfere with crimping operations on Parker 881-16 hose (1” hydraulic suction and return line). Hose crimper and ancillary items (hydraulic pump and pneumatic pump) shall be mounted or be able to be positioned so that one soldier can complete crimping operations.

3.2.5 Layout. Equipment shall be organized in a manner to facilitate ease of use by the th to the 95 th percentile soldier. Basic U.S. Army anthropometrics charts and applicable

DOD human engineering guidelines are provided in Appendix B. All equipment and consumables shall be accessible by personnel standing on the ground next to the HSTRU or a means shall be provided to access those inaccessible items. Items that are used together shall be stored together and items required for setup and emergencies shall be located in readily accessible areas by personnel standing on the ground next to the

HSTRU.

3.2.6 Training Consumables. All tools listed in Appendix G: Training Consumables shall be provided by the contractor. These items shall be stored with like items of the tool load when possible, however the auxiliary cabinet may be used to store small parts. These items are exempt from the rapid inventory requirements as they are provided for training purposes and will be used during fielding.

3.3 Inputs and interfaces.

3.3.1 Enclosure/trailer. The outfit shall be mounted on a Chassis, Trailer, Two-Wheel, NSN 2330-01-387-5424 and suitable for towing by the heavy series of HMMWVs (e.g.

M1097, M1114) that have a rated towing capacity of 4000 lbs. None of the outfit components or tools shall be transported in the towing HMMWV or on another vehicle.

All components shall be contained inside the enclosure. Tire pressure shall be 17 ±0.5 psi. The trailer at GVW shall have a minimum ground clearance of 16”. Trailer departure angle at GVW shall be a minimum of 38 degrees. Clearance around the tires shall be sufficient to not interfere with trailer operation. No components shall be welded to the chassis

3.3.1.1 Government Furnished Material (GFM) modification. The contractor may modify Government-furnished tactical trailers as necessary to meet the requirements of this specification, provided the safety and performance of the HMMWV and trailer are not compromised. Modifications shall be approved by the Contracting Officer.

3.3.1.2 Size. When ready for transport the overall width of the trailer with enclosure shall not exceed 86.3 inches, length shall not exceed the foot print of the trailer (96 inches) and overall height shall not exceed 85 inches.

3.3.2 Physical security. The enclosure shall be lockable and provide physical security for all internally stored or mounted equipment and supplies sufficient to discourage tampering, unauthorized use, and theft.

3.3.2.1 Locks. Locking of the enclosure shall be accomplished with padlocks. The hasps and staples or other locking devices incorporated in the enclosure shall accept key-operated, tumbler-type padlocks conforming to CID A-A-59487-2, which have shackles with a diameter of 0.343 ±0.040 inch. All external doors and openings shall be secured with such locks and shall be furnished by the contractor. Lock sets shall use a single key for each HSTRU, while each HSTRU shall use a unique key.

3.3.2.2 Anti-tampering measures. When the enclosure is prepared for transport and storage, the padlock(s) shall be plainly visible on the enclosure exterior. It shall not be possible to use or remove any of the components stored in the enclosure without either removing the locks or visibly damaging the enclosure.

3.3.3 Loss and damage prevention. All doors, panels, and other covers for openings in the enclosure shall be permanently affixed to the enclosure. NOTE: Because vertically hinged doors are more readily damaged than other types, and constitute a hazard to personnel when slammed open or shut by a gust of wind, they are the least-preferred type of opening. Roll-up or other innovative door designs are the most preferred type.

3.3.3.1 Door static load. Vertically hinged doors (if used) shall be capable of supporting a 200 lb downward load on the edge opposite the hinge without sustaining damage.

3.3.3.2 Wind gust load. All doors, panels, and other covers for openings in the enclosure shall be provided with latches, stays, or other mechanisms that hold them in the open position and prevent them from damage when subjected to wind gusts up to 60 mph normal to the surface.

3.3.4 Electrical.

3.3.4.1 Electrical inlet. The enclosure shall be equipped with a permanently-mounted weatherproof straight blade inlet and cover on the exterior of the enclosure similar to

Hubbell HBL61CM64 (commercial receptacles). The inlet shall be capable of accepting the power cord pigtail in the tool load. This inlet will power the trailer lights and accessories through the distribution box. The cable which powers the HSTRU (#28

Power cord with reel) shall be required to power the trailer from its storage location.

This requires that there is enough clearance around the reel to allow for winding and unwinding the reel. Also, the storage location shall permit the power pigtail (#27 Power cord pigtail) to reach from the reel to the inlet.

3.3.4.2 Power distribution. The NEMA standard distribution box shall provide two 20

Amp thermal circuit breakers, one for each circuit in the enclosure. The distribution box, conduit, junction boxes, and receptacle boxes shall be NEMA exterior grade weather-tight components, and all receptacles shall be provided with weather-tight covers.

3.3.4.3 Electrical outlets. Branch circuits and power outlets for electrical equipment shall be provided inside the enclosure. The enclosure shall be provided with at least two 120 volt, 20 Ampere circuits for electrical receptacles. Each circuit shall have at least two duplex 5-15R receptacles as defined by NEMA WD 6 placed within easy reach of the workbench.

3.3.5 Human interface. The HSTRU shall be suitable for setup, operation, and maintenance by the majority of U.S. Army personnel, from the fifth percentile to ninety-fifth percentile female and the fifth to ninety-fifth percentile male. Basic U.S. Army anthropometrics charts and applicable DOD human engineering guidelines are provided in Appendix B.

3.3.5.1 Task loading. The outfit shall be easy to set up for operation and to prepare for transportation. The tasks required to prepare the outfit for ground transport after operation, and likewise to prepare it for operation after ground transport, shall not require one soldier more than ten minutes.

3.3.5.2 Illumination level. The outfit enclosure is required to provide permanently mounted lighting for the workbench that is powered by the 120 V input power. The lighting system shall provide both visible spectrum white light and Night Vision Device

(NVD) safe light (i.e. blue-green light not detectable to NVDs) (see 3.4.2.2). The white lights shall provide general task illumination of at least 50 foot-candles (540 Lux), measured at the workbench surface, and the light shall be so distributed as to minimize glare and specular reflection. All items in the enclosure shall be illuminated to allow them to be removed from their storage location.

3.3.5.3 Protective clothing. The outfit shall be operable and maintainable by personnel wearing heavy gloves and clothing suitable for cold weather and body armor.

3.3.5.4 Storage.

3.3.5.4.1 Easy access. All equipment and expendable supplies in the enclosure shall be accessible by personnel standing outside the enclosure. To accommodate standing operation for personnel the distance from the ground to any overhead obstruction on the outside of the enclosure shall be at least 76 inches when in operational mode. An unobstructed height of 78 inches or more is preferred. The ease of manual mounting and dismounting, storage and retrieval of equipment required to convert the outfit from transport mode to operational mode and back is an important consideration.

3.3.5.4.2 Organized storage. Each item carried in the enclosure shall have a specifically designated storage location and secured in place to prevent damage to the component or enclosure. The storage methods employed shall provide a probability of at least 80 percent that the operator can locate any individual component required to perform a maintenance mission in 2 minutes or less.

3.3.5.4.3 Proximate storage. Items normally used together shall be stored in the same area of the enclosure.

3.3.5.4.4 Linear products. Flexible linear products more than ten feet long, such as hoses and electrical cords, that are required in addition to the tools, equipment and supplies provided by the government, shall be stored on reels or looms. Straps, ties, or other devices shall be provided for linear products not stored on reels or looms to permit them to be stored and hand-carried in neat coils. Storage shall be provided for up to 6’ long steel tubing and shall allow any length 6’ or shorter to be easily accessed.

3.3.5.4.5 Visual cues. The storage method used for each item shall provide the operator a visual cue when an item is not in its designated storage location.

3.3.5.4.6 Rapid inventory. The integration of the outfit tools and equipment into the enclosure shall facilitate rapid inventory. The storage methods employed shall provide a probability of at least 80 percent that the operator can verify within 15 minutes or less that all items in the outfit are present and secured in their designated storage locations. In the event an item is absent from the outfit, the operator shall be provided with the means to identify the specific item by name and description. There shall be a probability of at least 0.8 that any missing item be identifiable by name and NSN; or by name, part number, and supplier’s CAGE code; within three minutes.

3.3.5.5 Plates and labels. All identification, warning, and instruction plates and labels shall be permanently affixed to the enclosure or individual components of the outfit, as required by Manpower and Personnel Integration (MANPRINT). 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 outfit. Marking shall be accomplished in a manner that does not adversely affect the life and utility of the outfit or its equipment. All human readable plates and labels shall be printed in the English language, and may be supplemented by graphical symbols. Plates and labels shall be in accordance with ANSI Z535.4.

3.3.5.5.1 Item identification. A human readable information plate conforming to A-A-

50271, Composition A, Class 2 or Composition D, and containing the following data shall identify each HSTRU in accordance with MIL-STD-130. The item identification shall be placed in a location on the exterior of the HSTRU enclosure that is plainly visible when the enclosure has been closed in preparation for transport or storage.

a. Nomenclature: (to be identified by contract/delivery order)

b. NSN: (to be identified by contract/delivery order)

c. LIN: (This is the property accountability number to be identified by contract/delivery order)

d. Specification data: DFP ECB-008

e. Manufacturer: CAGE or NSCM and PIN **

f. Serial Number: *

g. Acquisition instrument identification number: **

* Format optional

** See definitions

3.3.5.5.2 Shipping data. A human readable shipping data plate shall be furnished for each HSTRU enclosure and shall conform to A-A-50271, Composition A, Class 2 or composition D. Silhouettes of the trailer-mounted HSTRU in transport configuration that indicate the center of gravity of the fully-loaded trailer along each axis as well as the locations of the lifting and tie-down provisions shall be included on the data plate. The shipping data plate shall be placed in a location on the exterior of the HSTRU enclosure that is plainly visible when the enclosure has been closed in preparation for transport or storage.

3.3.5.5.3 Hazard identification. Unguarded physical hazards (see paragraph 3.5.2) shall be identified by human readable information plates. Product safety signs and labels shall conform to ANSI Z535.4.

3.3.5.5.3.1 Noise hazards. If the steady-state noise produced by the compressor(s) or other HSTRU components in any mode of operation exceeds 85 decibels (dB) on the A-weighted scale, noise hazard caution signs that require the operator to wear hearing protection shall be posted on the compressor or other component in conspicuous locations.

3.3.5.5.3.2 Lift hazards. Caution signs shall be provided for stored items that exceed the safe limits for a single person to lift using both hands (see Appendix B).

3.3.5.5.4 Warrantee information. A human readable warranty information plate at least 5 inches wide and 2.5 inches high shall be furnished for each HSTRU enclosure. The warranty information plate shall be located in a conspicuous location near the workbench and shall conform to the following image.

3.3.5.5.5 Unique Item Identification. Each HSTRU enclosure shall be marked with a

Unique Item Identifier (UID) that has machine-readable data elements distinguishing it from all other like and unlike items in accordance with MIL-STD-130 (see note 6.5).

Each UID shall be globally unique and unambiguous. The UID data elements shall be contained in a Data Matrix ECC200 symbol in accordance with ISO/IEC 16022. Any component of the HSTRU for which the cost to the Government will exceed $5000 shall also be marked with a UID.

3.3.5.5.6 DD Form 1348-1A as applicable. When items are shipped via Rock Island

Arsenal a DD Form 1348-1A shall be completed per MIL-STD-129 and DoD 4000.25-1-

M, less field 24 (Document Number and Suffix). A Portable Document Format of this form will be provided. Two copies of the form shall be placed in a water-resistant envelope and securely attached to the outside of each HSTRU.

A sample DD Form 1348, Issue Release/Receipt Document is shown below.

3.4 Environment.

3.4.1 Environmental protection. The HSTRU tool load includes spill containment equipment and supplies for maintenance operations involving hydraulic fluid and cleaning solvent. These items must be readily accessible by personnel standing at the workbench.

3.4.2 Survivability. The HSTRU must be survivable in the battlefield environment.

3.4.2.1 Protective coloration. For concealment, the exterior of the enclosure must be provided with a color scheme that will blend in with the operational environment.

Camouflage patterns must be supplied by the Army, and cannot be made available for new designs before the product verification inspection (if required) has been approved.

Unless and until otherwise specified by the contract, the exterior of the enclosure shall be a tan approximating color chip 33446 of FED-STD-595. Camouflage patterns supplied by the Army shall not be altered. Brackets or other hardware attached to the enclosure exterior shall be coated to match the camouflage pattern in that area.

3.4.2.2 Blackout conditions. The operator shall be able to switch from white light to

NVD-safe lighting by operating a single switch. The single switch which changes the lights to NVD-safe lighting mode shall also extinguish all non NVD-safe lights. The lens of the NVD-safe light shall have the following characteristics (Lens 12314082 has these characteristics). Wavelength of maximum transmittance 470-500 nm, transmittance at the maximum: >40%, Half-width (full width at half-height): 90-130 nm, Transmittance between 650-1200 nm: < 1% at any wavelength, Photopic transmittance with illuminant

A, (2854 K): 7-13%.

3.4.2.3 Nuclear, Biological, and Chemical Contamination Survivability. The trailer and the exterior and interior of the HSTRU enclosure will be nuclear, biological and chemical

(NBC) contamination survivable to the extent practicable. The tools, equipment, storage media, and expendable supplies mounted or stored in the shop enclosure need not be

NBC contamination survivable. Modifications to the trailer and/or enclosure, including the installation of brackets or other hardware on the exterior of the enclosure, shall not degrade the contamination survivability of the trailer or enclosure. The interior and exterior of the enclosure plus all shelving, brackets and hardware shall be protectively coated in a method that conforms to the requirements of MIL-STD-171, finish 7.3.1 plus

20.24 Chemical Agent Resistant Coating (CARC) for aluminum, and finish 5.1.1 plus

20.24 (CARC) for ferrous metals. (This is a military–unique requirement.) If the design provides for material other than metal, the material shall be certified to be NBC survivable or shall accept a CARC that lasts for the economic life of the HSTRU.

3.4.3 Operational environment. The HSTRU will be deployed to climatic design types hot, basic, and cold as defined by MIL-STD-810. It must be operable under all adverse weather conditions of the hot, basic, and basic hot climatic conditions, and withstand storage and transit conditions in the hot and cold climatic design types. Under basic cold climatic conditions the HSTRU will be operated in a heated shelter.

3.4.3.1 Operating temperatures. The HSTRU shall be operable when conditioned to air temperatures from -4 °F to +120 ºF (-20 ºC to 49 ºC) inclusive.

3.4.3.2 Storage and transport temperatures. The HSTRU, excluding COTS tools, shall withstand outdoor storage and transport in climatic design types hot, basic, and cold as defined by MIL-STD-810 without sustaining damage. The HSTRU will be stored and transported with all panels and doors closed. The HSTRU shall withstand storage in all air temperatures from -50 ºF to +160 ºF (-46 ºC to 71 ºC), inclusive.

3.4.3.3 Weather protection. The HSTRU enclosure shall protect its contents from rain;

from accumulations of ice and snow; and from accumulations of road dirt, dust, and mud.

With doors and panels closed in the transport mode, the enclosure shall be watertight without the need for additional external sealing, calking, taping, etc. Weather seals shall be designed to be an integral part of the enclosure, and to be readily replaced by the user in the field without the use of special tools. The roof of the enclosure shall not allow water to puddle after precipitation.

3.4.3.4 Fungus and moisture. All hoses, electric cable covers and other elastomer parts that are exposed to air shall be fungus resistant.

3.4.3.5 Ozone. All hoses, electric cable covers and other elastomer parts exposed to air shall be ozone resistant.

3.4.3.6 Marine environment. The enclosure in transport mode and operating mode shall be resistant to a salt fog environment. There shall be no evidence of corrosion or degradation to any part of the enclosure (including but not limited to fasteners, hinges, and seals) after two cycles of 24 hours of salt fog exposure followed by 24 hours of drying.

3.4.3.7 Desert environment. The external and internal moving parts of the enclosure shall be designed to resist the effects of blowing sand.

3.5 Safety. The HSTRU shall not present any uncontrolled safety or health hazards throughout the life cycle of the system. The HSTRU shall incorporate the following features to assure safe operation.

3.5.1 Physical hazard control. Mechanical guards, electrical insulation, thermal insulation, and other safety devices shall be provided to protect operators and maintenance personnel from inadvertent contact with moving parts, electrically energized parts, high temperature surfaces, and other physical hazards (see Appendix B). The safety devices shall not interfere with operation of the HSTRU or its components.

Exposed sharp corners and sharp edges on HSTRU enclosure parts shall be eliminated if they serve no functional purpose. Hazards that cannot be eliminated, cannot be controlled by equipment placement, and cannot be controlled by protective devices shall be identified to the user by printed warnings or cautions.

3.5.2 Physical strain control. Caution signs (see paragraph 3.3.5.5.3.2) shall be provided for stored items that exceed the safe limits for single-person manual lift (see Appendix

B).

3.5.3 Component restraints. Doors, drawers, and other moving parts of the storage media shall be provided with restraints as necessary to secure them in the open and closed positions. The restraints shall prevent unintended movement of the moving parts due to transport (see paragraph 3.6). Items stored in the HSTRU enclosure shall be provided with restraints to secure them in place. The restraints shall prevent the stored items from being dislodged during transport or testing as specified in section 3.6. Restraints shall also prevent stored items from being dislodged at angles up to 15 degrees from the horizontal.

3.5.4 Electrical ground. All electrical circuits incorporated in the enclosure shall be electrically grounded to the enclosure and trailer frames and to the power source ground through the electrical input cable. All electrical power outlets shall be provided with

Ground Fault Circuit Interruption (GFCI) protection. An unpainted ¼-inch diameter grounding stud and captive wing nut shall be provided on the enclosure in a clearly marked location. When the enclosure is set up for operation, the grounding stud location shall permit it to be connected to an earth ground with a grounding wire not more than six feet long. A grounding system is included in the HSTRU tool load. There shall be a dedicated storage location for the grounding kit inside the enclosure that allows it to be the first item removed for set-up and the last item stowed before transport.

3.5.5 Toxic materials. The enclosure shall be constructed of materials that, in their cured, dried, or other final processed state, do not present a health hazard to personnel during transportation, operation, or maintenance of the enclosure. Exposure of the enclosure to temperatures of 160 ºF for extended periods shall not result in accumulation of toxic vapors inside the enclosure that exceed the National Institute of Safety and Health

(NIOSH) Threshold Limit Values for the substances present.

3.6 Transportability. The trailer-mounted HSTRU shall be suitable for commercial and military shipment via air, sea, rail, and highway.

3.6.1 Lifting and tie down provisions. The HSTRU shall have lifting and tie down provisions conforming to MIL-STD-209. Use of the existing lifting and tie down provisions found on the trailer chassis is permitted, subject to the requirements of MIL-

STD-209 for the complete HSTRU. If spreader bars are required to accommodate lift by cable sling, the enclosure shall incorporate integral spreader bars.

3.6.2 Shock and vibration. The fully-loaded trailer-mounted HSTRU shall withstand the shocks and vibration associated with commercial shipment as secured cargo without sustaining damage or degradation in performance. During or following shipment, there shall be no damage to or displacement of any component, accessory, part, or tool installed in or on the enclosure, and no evidence of damage to the enclosure or trailer.

3.6.3 Rail transport. In rail transport mode the fully-loaded trailer-mounted HSTRU shall withstand, without damage to or displacement of any stored component or damage to the enclosure, the shock and vibration imparted by coupling rail cars at impact speeds up to 8 miles per hour (mph).

3.6.4 Air transport. The fully-loaded trailer-mounted HSTRU shall be suitable for transport by the U.S. Air Force C130 and larger cargo aircraft and for external airlift by helicopter.

3.6.4.1 Cargo aircraft. The HSTRU enclosure shall be capable of withstanding an internal pressure differential of 8.3 psi (0.57bar) developed within 0.5 sec or less without catastrophic failure that allows any part of the HSTRU to become a projectile. The installation of HSTRU tools and other components shall not interfere with the operation of this feature, and the vent(s) shall not be blocked. If the HSTRU is to be lifted by a fork lift and the weight is not evenly distributed, center of balance markings shall be applied in accordance with Section 5.2.17 of MIL-STD-129.

3.6.4.2 Helicopter external lift. The fully loaded enclosure shall be certified suitable for

External Air Transport (EAT) (sling load) by CH-47 and larger cargo helicopters in accordance with MIL-STD-913 in one lift.

3.6.5 Military ground transport. The fully-loaded trailer-mounted HSTRU shall be suitable for transport by heavy HMMWVs as a towed package.

3.6.5.1 Weight. The weight of the fully-loaded trailer-mounted HSTRU when prepared for ground transport the trailer shall to exceed 4000 lbs. The weight of the tools and other items in the outfit Component List (see Appendix A) is subject to variation, depending on the specific items procured; the approximate total weight is 1700 lbs.

3.6.5.2 Balance. When prepared for transport, the weight of the fully-loaded trailer-mounted HSTRU shall be properly balanced. The center of gravity (CG) shall be within

6 inches of the longitudinal centerline of the trailer and so located that the lunette/pintle load is not less than 210 lbs and not more than 420 lbs. The maximum allowable CG height of the fully-loaded trailer-mounted HSTRU in transport mode shall be 45 inches.

3.6.5.3 Ground Mobility. The fully-loaded trailer-mounted HSTRU shall have the durability to withstand being transported over a variety of surfaces including 30% on primary roads, 65% on secondary roads, and 5% on open cross-country. The surfaces traversed shall include various states of disrepair that may be encountered worldwide, including bumps, cobblestone, and washboard. During or following the travel, there shall be no damage to, or displacement of, any component, accessory, part, or tool installed in or on the shop and no evidence of damage to the enclosure. Maximum safe speed for the surface and conditions shall be maintained; not to exceed 55 mph on primary roads, 35 mph on secondary roads, and 20 mph for travel cross-country. The HSTRU shall be capable of ascending or descending in forward or reverse, starting and stopping on a 60 percent grade dry hard surface slope with no degradation in driver control. In addition, the fully-loaded trailer-mounted HSTRU shall meet the performance criteria of Appendix

C.

3.7 Economic life. The HSTRU shall have a projected economic life of not less than 15 years under the service conditions described herein.

3.8 Stability. When set up for operation on level ground, a downward force of 250 pounds applied to the work surface shall not cause the trailer to tip.

3.9 Ease of maintenance.

3.9.1 Access. It shall be possible for the majority of Army personnel to perform preventative maintenance on the HSTRU enclosure without removing or disassembling any part of the storage media (see Appendix B).

3.9.2 Fastening devices. Screws, pins, bolts, and similar parts shall be installed with means for preventing loss of tightness. The methods for preventing loss of tightness shall be according to accepted engineering standards and practices. No such parts subject to removal or adjustment shall be swaged, staked, or otherwise deformed.

3.9.3 Cleaning. The enclosure shall be washable inside and out.

3.10 Reliability/Maintainability. Excluding the commercial off-the-shelf (COTS) tools and other equipment, the HSTRU shall provide a Mission Capable Status rate of 90% with 80% confidence. Maintenance of non GFE shall require no specialty tools.

3.11 Other Statements of Work (SOW). Requirements pertaining to technical publications, supply support and training aides shall be addressed in separately provided

SOWs.

4 VERIFICATION

4.1 General provisions. The inspections (examinations and tests) herein shall be performed to determine whether the item conforms to Section 3 of this specification.

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

4.1.2 Inspection conditions. Unless otherwise specified, all inspections shall be performed in accordance with the test conditions specified herein.

4.1.3 Inspection Phases and Locations. Appendix E lists the proposed locations for inspecting, testing and examining HSTRU product representative systems.

TABLE I. Requirement/verification matrix Verification Methods Verification Class

N – Not Applicable A = Product Verification

1 – Analysis B = Conformance

2 – Demonstration

3 – Examination

4 – Test (F = Product Verification only)

Title

Section 3

Requirement

Verification

Method

Verification

Class

Section 4

Requirement N 1 2 3 4 A B

Tools, equipment and supplies 3.2.1 X X 4.5

Tools, equipment and supplies other than those specified in the Tool Load

Appendix

3.2.1 X X 4.5

Workbench 3.2.2 X X 4.5.1

Vise mount 3.2.3 X X 4.5.2

Hose Crimper 3.2.4 X X 4.5.3

Layout 3.2.5 X X 4.5.4

Training Consumables 3.2.6 X X 4.5.5

Enclosure/trailer 3.3.1 X X 4.6.1

GFM modification 3.3.1.1 X X 4.6.1.1

Size 3.3.1.2 X X 4.6.1.2

Locks 3.3.2.1 X X X 4.6.2.1

Anti-tampering measures 3.3.2.2 X X 4.6.2.2

Loss and damage protection 3.3.3 X X 4.6.3

Door static load 3.3.3.1 X X 4.6.3.1

Wind gust load 3.3.3.2 X X 4.6.3.2

Electrical inlet 3.3.4.1 X X 4.6.4.1

Power distribution 3.3.4.2 X X 4.6.4.2

Electrical outlets 3.3.4.3 X X 4.6.4.3

Human interface 3.3.5 X X 4.6.5

Task loading 3.3.5.1 X X 4.6.5.1

Illumination level 3.3.5.2 X X 4.6.5.2

Protective clothing 3.3.5.3 X X 4.6.5.3

Easy access 3.3.5.4.1 X X 4.6.5.4.1

Organized storage & Visual Cues 3.3.5.4.2 &

3.3.5.4.5

X X X 4.6.5.4.2

Proximate storage 3.3.5.4.3 X X X 4.6.5.4.3

Linear products 3.3.5.4.4 X X X 4.6.5.4.4

Rapid inventory 3.3.5.4.6 X X 4.6.5.4.5

Plates and labels 3.3.5.5 X X 4.6.6

Item identification 3.3.5.5.1 X X X 4.6.6.1

Shipping data 3.3.5.5.2 X X X 4.6.6.2

Hazard identification 3.3.5.5.3 X X X 4.6.6.3

Noise hazards 3.3.5.5.3.1 X X X 4.6.6.3.1

Lift hazards 3.3.5.5.3.2 X X X 4.6.6.3.2

Warrantee Information 3.3.5.5.4 X X X 4.6.6.4

Unique Item Identification 3.3.5.5.5 X X X 4.6.6.5

DD Form 1348 3.3.5.5.6 X X X 4.6.6.6

Environmental protection 3.4.1 X X X 4.7.1

Protective coloration 3.4.2.1 X X X 4.7.2.1

Blackout conditions 3.4.2.2 X X 4.7.2.2

Nuclear, Biological, and Chemical

Contamination Survivability

3.4.2.3 X X 4.7.2.3

Operational temperature 3.4.3.1 X X 4.7.3.1

Storage temperature 3.4.3.2 X X 4.7.3.2

Weather protection 3.4.3.3 X X 4.7.3.3

Fungus and moisture 3.4.3.4 X X 4.7.3.4

Ozone 3.4.3.5 X X 4.7.3.5

Marine environment 3.4.3.6 X X 4.7.3.6

Desert environment 3.4.3.7 X X 4.7.3.7

Physical hazard control 3.5.1 X X X 4.8.1

Physical strain control 3.5.2 X X X 4.8.2

Component restraints 3.5.3 X X 4.8.3

Electrical ground 3.5.4 X X X 4.8.4

Toxic materials 3.5.5 X X 4.8.5

Transportability 3.6 X X 4.9.1

Lift and tiedown provisions 3.6.1 X X 4.9.2

Shock and vibration 3.6.2 X X 4.9.3

Rail transport 3.6.3 X X 4.9.4

Cargo Aircraft 3.6.4.1 X X 4.9.5.1

Helicopter EAT 3.6.4.2 X X 4.9.5.2

Military ground transport 3.6.5 X X 4.9.6

Weight 3.6.5.1 X X 4.9.6.1

Balance 3.6.5.2 X X 4.9.6.2

Ground Mobility 3.6.5.3 X X 4.9.6.3

Economic life 3.7 X X 4.10

Stability 3.8 X

Access 3.9.1 X X 4.12.1

Fastening devices 3.9.2 X X X 4.12.2

Cleaning 3.9.3 X X X 4.12.3

Reliability/Maintainability 3.10 X X 4.11

Other Statements of Work 3.11

4.2 Product verification inspection.

4.2.1 Submission. The contractor shall submit a product representative system as designated by the Contracting Officer for evaluation in accordance with the specified verification methods of Table I.

4.2.2 Inspections to be performed. As determined by the Government, the product representative system’s assemblies, components and test specimens may be subjected to any or all of the verification methods specified (see Table I). Unless otherwise specified all the inspections shall be performed.

4.2.3 Rejection. If any test assemblies, test specimen or test components fails to comply with any of the applicable requirements, the product representative system shall be rejected. The Government reserves the right to terminate inspection upon any failure of a test assembly, specimen or component to comply with any of the requirements.

4.3 Conformance inspection.

4.3.1 Compliance. Conformance inspections shall be applied to production units being offered for acceptance under the contract. These inspections shall include all verifications listed in Table I.

4.3.2 Inspection lot formation. Lot formation shall be in accordance with Section 4 of

MIL-STD-1916.

4.3.3 Sampling plan determination. Conformance verification methods are specified in

Table I. When required by contract or cited herein, attribute sampling inspections shall be conducted in accordance with MIL-STD-1916 using verification level I.

4.3.4 Rejection. Failure of any unit to pass any verification shall be cause for rejection of the unit and screening of the lot for the same defect.

4.4 Preparation. Prepare the HSTRU for testing by performing normal service, lubrication, and adjustment of the HSTRU components, enclosure, and trailer as recommended by the manufacturer.

4.5 Tools and related items. Verify that the HSTRU tools, equipment, and related supplies as specified in the Component List are present. Contractor supplied tools that differ from the Tool Load Appendix require verification that they meet or exceed the specifications of the specific tool.

4.5.1 Workbench. Verify a workbench is provided with the HSTRU enclosure. Measure the work surface dimensions and distance from ground level. The surface shall not be less than 30 inches wide and 16 inches deep. The work surface shall be 39 ± 3 inches from ground level with the enclosure trailer-mounted in operational mode. With a 20-oz striking hammer, apply several impacts, typical of repair shop operation, to various areas of the work surface. The work surface may be dimpled or dented, but shall have no chipping or fractures as a result of the hammer blows. Place a minimum dead weight of

250 pounds on the workbench surface and let it rest at least two (2) minutes. Move the dead weight to not less than 3 other positions on the surface. The dead weight shall not cover a surface area greater than 120 square inches at any time. There shall be no visible permanent deformation to the workbench or enclosure upon completion of the test.

Verify that mounts for the bench-mount equipment are provided on the workbench.

Verify that any equipment that must be dismounted from the workbench for transport have dedicated storage locations within the enclosure.

4.5.2 Vise mount. Verify that the vise can be adjusted without obstruction throughout the full range of motion provided by its design. In the jaws of the machinist’s vise, fasten a rod that is at least four (4) feet in length perpendicular to the workbench surface, and verify there is at least one position where no vertical obstruction exists. A minimal 45-pound test weight shall be clamped in the jaws of the machinist’s vice, and attach a standard torque wrench. Apply a 100 foot-pound torque to the test weight, first clockwise then counterclockwise, in planes that are parallel to and perpendicular to the horizontal centerline of the trailer. Examine the vise support for instability, insufficient rigidity, and visible permanent deformation. Evidence thereof shall be cause for rejection.

4.5.3 Hose Crimper. Verify the hose crimper is mounted in a location that provides adequate working room for hose crimping operations and is located a height that allows for use by 5 th to 95 th percentile female and 5 th to 95 th percentile males or a mechanical assist is provided that allows one soldier to position the crimper in such a position. The work surface or other components of the HSTRU shall not hinder hose crimping operations.

4.5.4 Layout. Requirements for equipment layout are listed throughout the DFP, while qualities of a good layout consists of; equipment arrangement on the work bench that allows for ease of hose fabricating and testing, heavy items positioned lower and towards the edge to facilitate access by 5 th to 95 th percentile females and males, maximum use of space to minimize enclosure size, minimal stacked items so that equipment can be accessed without moving unneeded equipment. Verify ease of use by conducting typical hose fabrication and hydraulic system tests.

4.5.5 Training Consumables. Verify that the HSTRU training consumables as specified in Appendix G are present. Contractor supplied tools that differ from the Tool Load

Appendix require verification that they meet or exceed the specifications of the specific component.

4.6 Interfaces.

4.6.1 Enclosure/trailer. Verify that the HSTRU tools and equipment are installed in trailer-mounted enclosures, and that the storage configuration does not require that any

HSTRU components or tools be transported in the HMMWV or on another vehicle.

4.6.1.1 GFM modification. Verify that permanent documentation exists for any contractor-made vehicle modifications.

4.6.1.2 Size. Verify that the overall width of the trailer-mounted HSTRU when transported does not exceed 90 inches, including any item(s) mounted to the enclosure or trailer exterior.

4.6.2 Physical security.

4.6.2.1 Locks. Verify that the locking of the HSTRU enclosure is accomplished with padlock(s), and that the hasp and staple or other locking devices incorporated in the

HSTRU enclosure accept key-operated, tumbler-type padlocks conforming to CID A-A-

59487-2, which have shackles with a diameter of 0.343 ±0.040 inch.

4.6.2.2 Anti-tampering measures. When prepared for transport and storage, verify that the padlocks on the HSTRU are plainly visible on the exterior and that it is not be possible to use or remove any of the equipment stored in the enclosure without either removing the locks or visibly damaging the enclosure.

4.6.3 Loss and damage prevention. Verify that all doors, panels, and other covers for openings in the enclosure are permanently affixed to the enclosure.

4.6.3.1 Door static load. Each vertically hinged door (if used on the enclosure) shall have a 200-lb (90-kg) downward load applied at the edge opposite from the hinge pivot with door open to 90°. The load shall be removed and the door examined after 30 minutes.

Evidence fracture or permanent deformation of hardware and binding of the door shall each be cause for rejection.

4.6.3.2 Wind gust load. A wind gust load test shall be performed on the enclosure hinged door(s) and removable panel(s) in the open position(s), held by their retaining device(s).

A fixture shall be attached to the midpoint of the retained edge of the door or panel that shall permit application of the following horizontal forces, using free running pulleys to transmit the forces from weights and a 1/4-in (6-mm) diameter steel cable (the enclosure and pulley frames shall be rigidly held in place): a) A static load equal to 10 lb/ft

(49 kg/m

) (i.e. 10 lb times exposed door area in square feet). b) A dynamic load of 50 ft-lb

(222 N) provided by a 50 lb (20 kg) weight dropped five times from a height of 12 in

(300 mm). This test shall be performed from both sides of the open door. Evidence of fracture or permanent deformation of hardware and binding of the door shall each be cause for rejection.

4.6.4 Electrical.

4.6.4.1 Electrical inlet. Verify the enclosure is equipped with a permanently-mounted three-conductor cord rated for 40 Amps at 120 V 60 Hz AC with insulation rated for 600 volts maximum. Verify the cable jacket material is certified to be oil, abrasion resistant, and to remain flexible at –25 degrees F. Verify that the cable assembly is at least 50’ long with a NEMA 5-15P terminal on one end and wired into the enclosure AC distribution box on the other end.

4.6.4.2 Power distribution. Verify the enclosure has a NEMA standard distribution box with two 20 Amp thermal circuit breakers, one for each circuit in the enclosure. Verify tha the distribution box, conduit, junction boxes, and receptacle boxes are NEMA exterior grade weather-tight components, and that all receptacles are provided with weather-tight covers.

4.6.4.3 Electrical outlets. Verify the enclosure has at least two 120 volt, 20 Ampere circuits for electrical receptacles. Verify that at least two duplex 5-15R receptacles on each circuit are located within easy reach of the workbench.

4.6.5 Human interface. Verify the HSTRU complies with the guidelines of Appendix B, and that its equipment and machinery are easily accessible and operable

4.6.5.1 Task loading. Demonstrate that the HSTRU can be readily set up for operation by one person in 10 minutes or less. When finished, demonstrate that the same operator can return all equipment to their storage locations, and prepare the HSTRU for transport within the same timeframe.

4.6.5.2 Illumination level. With the lights of the enclosure turned on, measure the light intensity at the workbench surface with a luminance meter. Confirm there are at least fifty (50) foot-candles of illumination, and that glare and specular reflection are visually tolerable.

4.6.5.3 Protective clothing. Verify the HSTRU can be set up for operation by troops wearing heavy gloves and winter gear; and ballistic armor.

4.6.5.4 Storage.

4.6.5.4.1 Easy access. Using operators that meet the anthropometrical requirements of

Appendix…