Spec_12366551_C_1_Winch.pdf

APPLICATION REVISIONS

NEXT ASSY USED ON LTR DESCRIPTION DATE APPROVED

12364500 M88A2 B REDRAWN WITH CHANGE 03-03-12 DMA

ERR GSD-U6584

C ERR GSDV7879 11-10-25 DMA

DISTRIBUTION STATEMENT A.

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED.

COPYRIGHT © 2011 BAE SYSTEMS

LAND AND ARMAMENTS L.P.,

U.S. COMBAT SYSTEMS

REV C C C C C

SHEET 32 33 34 35 36

REV C C C C C C C C C C C C C C C C C

SHEET 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

REV STATUS REV C C C C C C C C C C C C C B

OF SHEETS SHEET 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO 12366551

PMIC A CONTRACT NUMBER US ARMY TANK AUTOMOTIVE

UNLESS OTHERWISE SPECIFIED DAAE07-94-C-0429 AND ARMAMENTS COMMAND

DIMENSIONS ARE IN INCHES CONTRACTOR WARREN, MICHIGAN 48397-5000

TOLERANCES ON: UNITED DEFENSE, L.P.

2 PLACE 3 PLACE GROUND SYSTEMS DIVISION PRODUCTION SPECIFICATION

+ + DRAWN BY DATE (YR-MO-DA) FOR MAIN WINCH ASSEMBLY,

JUDY 96-04-18 12364530

CHECKER ENGINEER

TV

SIZE CAGE CODE

DRAWING

APPROVAL

C FILUS A 19207 12366551

MATL ENGRG QAP APPROVAL DESIGN APPROVAL

R L ROBINSON SCALE: NONE UNIT WT - SHEET 1 OF 36

Table of Contents

Section Page No

1. Scope 6

1.1 Scope 6

2. Applicable Documents 6

2.1 Government Documents 6

2.1.1 Specifications, Standards and Handbooks 6

2.2 Non-Government Documents 7

3. Requirements 8

3.1 Definition 8

3.2 Characteristics 8

3.2.1 Performance 8

3.2.1.1 Line Pull 8

3.2.1.2 Line Speed 8

3.2.1.2.1 Loaded Line Speed 9

3.2.1.2.2 Unloaded Line Speed 9

3.2.2 Physical Characteristics 9

3.2.2.1 Weight 9

3.2.2.2 Envelope 9

3.2.2.3 Lifting Eyes 9

3.2.2.4 Interfaces 9

3.2.2.5 Health 10

3.2.2.6 Durability 10

3.2.3 Reliability 11

3.2.4 Maintainability 11

3.2.5 Environmental 11

3.3 Design and Construction 13

3.3.1 Materials, Processes, and Parts 13

3.3.1.1 Material Deterioration Prevention and Control 13

3.3.1.2 Dissimilar Metals 13

3.3.1.3 Identification of Materials and Finishes 13

3.3.1.4 Qualified Products 13

3.3.1.5 Ozone Resistance 13

3.3.1.6 Hydraulic Fluid Compatibility 14

3.3.1.7 Winch Brake and Clutch 14

3.3.1.8 Spooling Roller 14

3.3.1.9 Layer Sensor 15

3.3.1.10 End of Wire Rope Sensor 15

3.3.1.11 Diamond Screw 15

3.3.1.12 Hydraulic Components 15

SIZE

A

CAGE CODE

19207

12366551

REVISION LEVEL

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COPYRIGHT © 2011 BAE SYSTEMS

LAND AND ARMAMENTS L.P.,

U.S. COMBAT SYSTEMS

DISTRIBUTION IS UNLIMITED.

SEE SHEET 1 FOR DISTRIBUTION STATEMENT.

Table of Contents (Continued)

3.3.1.12.1 Hydraulic Motor 15

3.3.1.12.2 Counterbalance Valve 16

3.3.1.12.3 Cross-Port Relief Valve 16

3.3.1.12.4 Hydraulic Lines 16

3.3.1.12.5 Hydraulic Cleanliness 16

3.3.1.12.6 Test Ports 17

3.3.1.13 Electrical Components 17

3.3.1.14 Drum 17

3.3.1.15 Lubricating Oil 17

3.3.1.16 Seals 17

3.3.2 Shock, Vibration, and Electromagnetic Radiation 17

3.3.3 Painting, Marking, and Data Plates 17

3.3.3.1 Painting 18

3.3.3.2 Marking 18

3.3.3.3 Data Plates 18

3.3.4 Workmanship 19

3.3.5 Parts Interchangeability 19

3.3.6 Safety 19

3.4 Personnel 19

3.5 Order of Precedence 20

4. Quality Assurance Provisions 20

4.1 General 20

4.1.1 Quality Assurance Inspection Articles 20

4.1.2 Quality Assurance Terms 20

4.1.3 Responsibility for Inspection 20

4.1.3.1 Responsibility for Compliance 21

4.1.3.2 Inspection Equipment 21

4.1.3.3 Inspection Records 21

4.1.3.4 Verification 22

4.1.4 Inspection and Test Conditions 22

4.1.4.1 Fluid Leakage Defects 22

4.1.4.2 Government Operational Testing 22

4.1.5 Special Tests and Examinations 22

4.1.5.1 Classification of Inspection 23

4.1.5.2 First Article Test (FAT) 23

4.1.5.2.1 First Article Test Failures 23

4.1.5.3 Component Acceptance Test (CAT) 25

4.1.5.3.1 Component Acceptance Test Failures 26

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4.1.5.4 Quality Conformance Inspection (QCI) 26

4.1.5.4.1 Winch QCI Test 26

4.1.5.4.2 Winch QCI Failures 27

4.2 Characteristics 27

4.2.1 Performance Inspection Methods 27

4.2.1.1 Line Pull 27

4.2.1.2 Line Speed 28

4.2.1.2.1 Loaded Line Speed 28

4.2.1.2.2 Unloaded Line Speed 28

4.2.2 Physical Characteristics 28

4.2.2.1 Weight 28

4.2.2.2 Envelope 28

4.2.2.3 Lifting Eyes 28

4.2.2.4 Interfaces 28

4.2.2.5 Health 28

4.2.2.6 Durability 29

4.2.3 Reliability 29

4.2.4 Maintainability 29

4.2.5 Environmental 29

4.3 Design and Construction 30

4.3.1 Materials, Processes and Parts 30

4.3.1.1 Material Deterioration Prevention and Control 30

4.3.1.2 Dissimilar Metals 30

4.3.1.3 Identification of Materials and Finishes 30

4.3.1.4 Qualified Products 30

4.3.1.5 Ozone Resistance 30

4.3.1.6 Hydraulic Fluid Compatibility 30

4.3.1.7 Winch Brake and Clutch 31

4.3.1.8 Spooling Layer 31

4.3.1.9 Layer Sensor 31

4.3.1.10 End of Wire Rope Sensor 31

4.3.1.11 Diamond Screw 32

4.3.1.12 Hydraulic Components 32

4.3.1.12.1 Hydraulic Motor 32

4.3.1.12.2 Counterbalance Valve 32

4.3.1.12.3 Cross-Port Relief Valve 32

4.3.1.12.4 Hydraulic Lines 32

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4.3.1.12.5 Hydraulic Cleanliness 32

4.3.1.12.6 Test Ports 32

4.3.1.13 Electrical Components 32

4.3.1.14 Drum 33

4.3.1.15 Lubricating Oil 33

4.3.1.16 Seals 33

4.3.2 Electromagnetic Radiation 33

4.3.3 Painting, Marking, and Data Plates 33

4.3.3.1 Painting 33

4.3.3.2 Marking 33

4.3.3.3 Data Plates 33

4.3.4 Workmanship 33

4.3.5 Parts Interchangeability 33

4.3.6 Safety 34

4.4 Personnel 34

4.5 Preparation for Delivery Inspection 34

5. Preparation for Delivery 34

5.1 General 34

5.2 Preservation, Packaging and Packaging Requirements 34

5.3 Marking for Shipment 34

6. Notes 34

6.1 Intended Use 34

6.2 Ordering Data 35

10. Appendix 35

10.1 Scope 35

10.2 Winch Wire Rope 35

10.2.1 Operational Wire Rope Length 35

10.2.2 Drum Rope Capacity 35

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1. SCOPE

1.1 Scope. This specification, 12366551, establishes the requirements for the main winch to be used on the M88A2 HERCULES, (ATPD 2150), (see 6.1).

2. APPLICABLE DOCUMENTS

2.1 Government documents

2.1.1 Specifications, standards and handbooks. The following documents form a part of this specification 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 contract or purchase order (see 6.2).

MILITARY SPECIFICATIONS

MIL-P-514 Plates, Identification, Instructions and Marking, Blank

MIL-C-5501 Caps and Plugs, Protective, Dust and Moisture Seal

MIL-P-14232 Packing of Parts, Equipment and Tools for Army Material

MIL-C-22750 Coating, Epoxy, High-Solids

MIL-PRF-46170 Hydraulic Fluid, Rust Inhibited, Fire Resistant Synthetic Hydrocarbon Base

MIL-R-83485 Rubber, Fluorocarbon Elastomer Improved Performance at Low Temperature

MILITARY STANDARDS

MIL-STD-129 Marking for Shipment and Storage

MIL-STD-130 Identification Marking of US Military Property

MIL-STD-461 Electromagnetic Emission and Susceptibility Requirements for the Control of Electromagnetic Interference

MIL-STD-462 Electromagnetic Interference Characteristics, Measurement of

MIL-STD-810 Environmental Test Methods and Engineering Guidelines

MIL-STD-882 System Safety Program Requirements

MIL-STD-889 Dissimilar Metals

MIL-STD-1184 (AT) Electrical Components for Automotive Vehicles; Waterproofness Tests

Unless otherwise indicated, copies of federal and military specifications, standards, and handbooks are available from the Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.

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LAND AND ARMAMENTS L.P.,

U.S. COMBAT SYSTEMS

PURCHASE DESCRIPTIONS

Army ATPD 2150 Improved Recovery Vehicle, Full-Tracked

ARMY REGULATIONS

AR 70-38 Research, Development, Test and Evaluation of Materiel for Extreme Climatic Conditions

ARMY DRAWINGS

12478271 Electrical Installation

12364530 Main Winch Assembly

12364546 Main Winch Wire Rope Assembly

12478341 Hydraulic Installation

12364865 Hydraulic Schematic

12367052 Electrical Wiring Diagram

12364895 Main Winch and Spade Installation

12364943 Manifold

12369002 Paint Systems for Aluminum, Interior Surfaces, White

12369004 Paint Systems for Steel, Interior Surfaces, White

12369023 Paint Systems for Pretreated Surfaces

Unless otherwise indicated, copies of the Purchase Description, Army Regulations and drawings are available from the contracting agency or as directed by the contracting officer.

2.2 Non-government documents. The following document(s) form a part of this specification to the extent specified herein. Unless otherwise specified, the issue of the documents which are DoD adopted shall be those listed in the issue of the DODISS specified in the contract or purchase order.

Unless otherwise specified, the issue of documents not listed in the DODISS shall be the non-government documents that are current on the date of the contract or purchase order.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D2000 Standard Classification System for Rubber Products in Automotive Applications

Applications for copies should be addressed to American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA, 19103.

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SOCIETY OF AUTOMOTIVE ENGINEERS

SAE J1165 Reporting Cleanliness Levels of Hydraulic Fluids SAE J2360 Lubricating Oil, Gear, Multipurpose (Metric) Military Use

Applications for SAE standards should be addressed to the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA, 15096-0001.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 8402 Quality Management and Quality Assurance - Vocabulary

ISO 10012-1 Quality Assurance Requirements for Measuring Equipment - Part 1

Applications for ISO standards should be addressed to the American National Standards Institute (ANSI), 11 West 42nd Street, New York, NY 10036.

3. REQUIREMENTS

3.1 Definition. The winch as used in this specification is an assembly consisting of the winch assembly, lever assembly, roller assembly, counterbalance valve, motor, valve and tube assemblies and all other parts comprising the main winch as shown on drawing 12364530.

3.2 Characteristics.

3.2.1 Performance.

3.2.1.1 Line pull. The hydraulic control integral to the winch shall limit line pull to the same value on all three wire rope layers. The winch shall provide a stall line pull of 140,000 pounds + 10% on all three wire rope layers with a supply pressure of 4,200 psi to the hydraulic motor inlet and 100 psi at the outlet (see 4.1.3.4, 4.2.1.1 and 10.2).

3.2.1.2 Line speed.

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3.2.1.2.1 Loaded line speed. Inhaul speeds with external loading shall not be less than the following:

a) Full load, running/low speed at 15 feet per minute.

b) Low load (less than 10,000 lbs)/high speed at 65 feet per minute.

These requirements are to ensure that inhauls conducted under both full load and low load can be accomplished within reasonable time constraints. Full load/low line speed shall be at the nominal flow rate of 50 GPM and the nominal motor pressure drop of 3900 psi.

Low load/high line speed shall be at the nominal flow rate of 50 GPM and the nominal motor pressure drop developed at the applied (low) loading condition (see 4.2.1.2.1 and 10.2).

3.2.1.2.2 Unloaded line speed. Inhaul speed with no external load (i.e., wire rope only) shall be a minimum of 5 feet per minute with a supply pressure of 1,500 psi and a flow of 6.9 GPM to the motor inlet; this requirement is to ensure that the wire rope can be retrieved within an acceptable time period when the winch is powered by the vehicle Auxiliary Power Unit (APU). The winch shall be capable of powered payout with the wire rope under load (see 4.2.1.2.2 and 10.2).

3.2.2 Physical characteristics.

3.2.2.1 Weight. The weight of the winch, less fluids, shall be no more than 3,800 pounds (see 4.2.2.1).

3.2.2.2 Envelope. The winch envelope shall be that defined on drawing 12364530 (see

4.2.2.2).

3.2.2.3 Lifting eyes. The winch shall have integral lifting eyes, which will remain within the installed envelope shown on drawings 12364895 (Main Winch and Spade Installation) and 12364530 (Main Winch Assembly) (see 4.2.2.3).

3.2.2.4 Interfaces. The winch shall interface, as applicable, with other items as shown on drawings 12364530 (Main Winch Assembly), 12364895 (Main Winch and Spade Installation), 12364850 (Hydraulic Installation), 12364352 (Electrical Installation), 12364865 (Hydraulic Schematic) and 12367052 (Electrical Wiring Diagram) (see 4.2.2.4).

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3.2.2.5 Health. The winch shall not present any health problems that may have a catastrophic or critical health hazard rating per MIL-STD-882. There shall be no asbestos used in any item of the winch (see 4.2.2.5).

3.2.2.6 Durability. Winch components shall be designed to minimize wear from wire rope rubbing and debris from winching operations. Winch gear train design shall incorporate the highest AGMA Gear Quality Numbers consistent with the overall requirements of this specification. The gearbox shall use MIL-L-2105 Multipurpose gear oil. The desired life of the winch is 20 years or 1,800 hours, when operated in accordance with the peacetime Operational Mode Summary/Mission Profile (OMS/MP). See Table I below (see 4.2.1.3).

Table I. Peacetime OMS/MP

1. Peacetime Life = 20 years

2. Winch Annual Peacetime Usage = 90 hours

Annual winch operations can be assumed to be distributed as follows:

Est. Operating % of Stall Load % of Oper. Time Time @ Stall

90% 5% 4.5 hrs.

80% 20% 18.0 hrs.

70% 15% 13.5 hrs.

60% 60% 54.0 hrs.

NOTE: Stall line pull is 140,000 pounds +/- 10% on all three wire rope layers with a supply pressure of 4,200 psi to the hydraulic motor inlet and 100 psi at the outlet.

A duty cycle can be considered as full cable extension to the item being "recovered" followed by winching in at the loads specified above (i.e., 90%, 80%, 70%, or 50% of stall) for 25 feet of wire rope; thereafter winching in at a reduced load of 45,000 to 50,000 pounds.

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3.2.3 Reliability. After proper installation in the intended use vehicle (see 6.1) and initial adjustment, the winch shall have a Mean Time Between Hardware Mission Failure (MTBHMF) of not less than 240 hours of operation demonstrated at a 0.70 confidence level in accordance with Section 4.2.3. A hardware mission failure is defined as the event or inoperable state of the winch or winch component, attributed or chargeable to hardware, which prevents the completion of a mission essential function as defined in the Failure Definition and Scoring Criteria, Annex F of ATPD 2150. Conditions during winch operation shall include any of the types of vehicle operation, terrain conditions, and ambient temperatures to which the M88A2 HERCULES is subjected to in accordance with the provisions of ATPD 2150.

Winch operations can be assumed to be distributed as follows: 5% @ 90% of stall; 20% @

80% of stall; 15% @ 70% of stall; and 60% @ 50% of stall (see 3.2.1.1) for the definition of stall). A duty cycle can be considered as full cable extension to the item being "recovered" followed by winching in at the loads specified above (i.e., 90%, 80%, 70%, or 50% of stall) for 25 feet of wire rope; thereafter winching in at a reduced load of 45,000 to 50,000 pounds (see 4.2.3).

3.2.4 Maintainability. The maintainability characteristics of the production winches shall be at least equivalent to that of the prototype winches provided for M88A2 Pre-production Qualification Test (PPQT). It is desirable that the winch shall require no more than one oil change after the initial 25 hours of operation. Beyond 25 hours, it is desirable that oil changes be on an “as required” basis rather than on a “scheduled” interval (see 4.2.4).

3.2.5 Environmental. The winch shall be capable of operation, storage, and transportation in climatic design types hot and basic as defined in AR 70-38 (see Table II). (See 4.2.5.)

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Table II. Climatic Design Types

OPERATIONAL CONDITIONS

STORAGE AND TRANSIT

CONDITIONS

CLIMATIC

DESIGN

TYPE

DAILY CYCLE

(QSTAG 360

EQUIVALENTS)

Ambient Air Temperature oF (oC)

Solar

Radiation Bph (W/m2)

Ambient Relative

Humidity

Induced Air Temperature oF (oC)

Induced Relative

Humidity

Hot-Dry (A1)

90 to 120 (32 to 49)

0 to 355 (0 to 1120)

3 to 8 91 to 160 (33 to 71)

1 to 7

Hot Hot-Humid (B3)

88 to 105 (31 to 41)

0 to 343 (0 to 1080)

59 to 88 91 to 160 (33 to 71)

14 to 80

Constant High

Humidity (B1)

Nearly Constant 75 (24)

Negligible

95 to 100

Nearly Constant 80 (27)

95 to 100

Basic

Variable High

Humidity (B2)

78 to 95

(26 to 35)

0 to 307

(0 to 970)

74 to 100

86 to 145 (30 to 63)

19 to 75

Basic Hot (A2)

86 to 110 (30 to 43)

0 to 355 (0 to 1120)

14 to 44 86 to 145 (30 to 63)

5 to 44

Basic Cold (C1)

-5 to -25 (-21 to -32)

Negligible Tending Toward

Saturation

-13 to -28 (-25 to -33)

Tending Toward

Saturation

NOTE: Extracted from Table 2-1, Summary of Temperature, Solar Radiation, and Relative

Humidity Daily Cycles, AR 70-38.

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3.3 Design and construction. Winch construction, design and assembly shall be in accordance with the main winch assembly drawing 12364530, as applicable.

3.3.1 Materials, processes, and parts. Materials, processes, and parts shall be compatible with the requirements of this specification and as specified in reference specifications, standards and drawings. Materials and parts shall be free of defects which adversely affect performance or serviceability of the finished product. Processes used shall not cause materials and parts deterioration or prevent the materials and parts from meeting the requirements specified herein (see 4.3.1).

3.3.1.1 Material deterioration prevention and control. The winch shall be fabricated from compatible materials, inherently corrosion resistant or treated to protect against, or by design protected from, the various forms of corrosion and deterioration that may be encountered in any of the applicable operating and storage environments to which the winch may be exposed over its useful life (see 3.2.5 and 4.3.1.1).

3.3.1.2 Dissimilar metals. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion. Dissimilar metals and methods of protection are defined and detailed in MIL-STD-889 (see 4.3.1.2).

3.3.1.3 Identification of materials and finishes. The contractor shall identify the specific material, material finish or treatment for use with component and subcomponent and shall make that specified information available, upon request, to the Government (see 4.3.1.3).

3.3.1.4 Qualified products. With respect to all assemblies and component parts requiring product qualification in accordance with the pertinent specifications or drawings listed herein, the contractor shall be responsible for using only those products which are listed by part or drawing number as Qualified Products List(s) (QPL) items on the QPL in the referenced specification or which have been approved for inclusion on such lists (see 4.3.1.4).

3.3.1.5 Ozone resistance. All new rubber components which are under tension or which may be flexed shall be ozone resistant as specified in ASTM D2000 (see 4.3.1.5).

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3.3.1.6 Hydraulic fluid compatibility. All materials in the hydraulic power and control sections shall be compatible with MIL-H-46170, Type I, hydraulic fluid. This fluid shall be used for all line pull, line speed (loaded and unloaded) and brake/clutch testing. Commercial hydraulic fluids may be used for non-loaded minor adjustments, leak checks and run-in, provided these fluids do not adversely affect either winch components or subsequent fills of MIL-H-46170, Type I, hydraulic fluid. Consideration should be given to the use of seals conforming to MIL-R-83485 (e.g., Parker Viton Compound V835-75) for reduced swell and longer life. The expected hydraulic fluid temperatures are as follows (see 4.3.1.6):

Ambient Air Temperatures - Sustained Conditions: -25 to 115° F Maximum Intermittent Condition: 120° F Storage Conditions (non operating): -28 to 160° F

Hydraulic Oil Temperatures - Normal Working or Circuit Temp.: 70 to 190° F Min. Start-Up (e.g., after overnight idle period): -25° F Localized Hot Spot (@ 115° F Ambient Air): 213° F

3.3.1.7 Winch brake and clutch. The winch shall have an integral spring applied brake with hydraulic release. A one-way clutch shall allow inhaul with the brake applied. Hydraulic pressure of 500 psi (nominal) shall release the brake during payout. The brake shall hold at least 154,000 pounds and prevent payout of wire rope in the event that hydraulic power is removed or the control placed in neutral.

When operating in the payin direction, application of the winch brake mechanism (i.e., brake and sprag clutch) shall prevent more than one inch of travel (measured along an arc generated by the drum pitch radius) in the payout direction. The brake and one way clutch shall perform without causing winch or hydraulic system chatter throughout the entire operating range and under all operating conditions specified herein (see 4.1.3.4, 4.3.1.7 and 10.2).

3.3.1.8 Spooling roller. Two integral spooling rollers and associated hardware shall be provided to ensure that the wire rope correctly spools onto the drum when the wire rope is payed in with no load. The spooling rollers shall be able to activate an electric signal should the wire rope spool beyond the drum flanges. All rollers shall be hardened to minimize wear (see 4.3.1.8 and 10.2).

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3.3.1.9 Layer sensor. An integral wire rope layer sensor and associated control system shall be provided to ensure that maximum line pull remains constant within +10% limits on all three wire rope layers. (see 3.2.1.1, 4.3.1.9 and 10.2).

3.3.1.10 End of wire rope sensor. The winch must automatically shut down to prevent payout beyond four (4) dead wraps. An integral end of wire rope sensor and associated hardware shall be provided which will activate an electric signal when four +1/2 wraps of wire rope are reached on the bare drum. This sensor function (end of wire rope) may be provided by one of the spooling rollers (see 4.3.1.10 and 10.2).

3.3.1.11 Diamond screw. A diamond screw mechanism shall be provided which is synchronized to drum rotation. The diamond screw mechanism shall provide a means of mechanically linking a control system to the winch for the purpose of synchronizing an external level wind device (to be provided by the Government) with drum rotation. The diamond screw shall be shielded with a two piece cover with a hinged joint, to prevent direct exposure to dirt (see 4.3.1.11).

3.3.1.12 Hydraulic components. All components of the winch hydraulic power transmission and control circuits exposed to maximum system working pressure shall have a rated working pressure of at least 5000 psi. The maximum system (i.e., design) working pressure is 4200 psi. Circuit components in the control and drain systems not exposed to maximum system working pressure will have adequate pressure ratings for their applications in accordance with sound engineering practices for mobile hydraulic equipment. The maximum flow rate to the main winch motor is 50 GPM (see 4.3.1.12).

3.3.1.12.1 Hydraulic motor. The winch shall be provided with a Rexroth Model

63, integral load sensing, variable displacement motor and associated motor control circuits. The motor shall use a 0.8 mm swivel time orifice in the control section. The motor’s G-port shall be plugged and shall not be used for external load sensing functions. A plug (Rexroth P/N 76117-001) shall be installed in the motor control section end cap in place of Rexroth check valve P/N 00930945. The Government will supply the operator's directional control valve and hydraulic plumbing to and from the motor. Adjustment screws on the motor shall be free of obstructions and accessible to maintenance personnel (see 4.3.1.12.1).

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3.3.1.12.2 Counterbalance valve. The winch shall be provided with an integral pilot-to-open assist, counterbalance valve and associated circuits. This is to ensure the positive load pressure is always maintained at the directional control valve during payout. The counterbalance valve shall maintain positive pressure on the payout port of the motor and prevent brake chatter during payout. The counterbalance valve shall prevent the drum rotation until system pressure is sufficient for level wind operation. Nominal counterbalance thermal relief pressure setting shall be 4500 psi with zero backpressure on the relief return port (designated port 2), corresponding to a system pressure of 1000 psi (4.5:1.0 pilot ratio). The counterbalance valve shall be rated for a flow of 120 gpm with flow fully restricted in the relief direction. A free flow check valve shall be provided in the bypass or inhaul direction. The pressure drop through the counterbalance valve in the bypass or inhaul direction (free flow) shall not exceed 50 psi at a flow rate of 50 gpm (see 4.3.1.12.2).

3.3.1.12.3 Cross-port relief valve. The winch shall be provided with an integral cross-port relief valve and associated circuits to ensure proper brake operation. Nominal relief pressure shall be 2800 psi with zero backpressure on the out or return port of the valve. (See 4.3.1.12.3).

3.3.1.12.4 Hydraulic lines. All hydraulic components integral to and located on the winch, will be plumbed by the winch supplier. The Government will provide all external hydraulic plumbing necessary to provide power, control, drain and return circuits, per winch drawing 12364530.

Routing of hydraulic lines on the winch shall be such that scheduled maintenance/adjustment procedures do not require removal or bending of any hydraulic line (see 4.3.1.12.4).

3.3.1.12.5 Hydraulic cleanliness. The winch shall be capable of meeting or exceeding all performance requirements specified herein while operating as part of the partially closed M88A2 HERCULES hydraulic system which is maintained at an ISO 16/13 rating level of cleanliness (ref. SAE J1165). Winch components shall be designed so as to minimize the entry of, or generation of, fluid contaminants. For shipping, all open hydraulic ports on the winch shall be plugged with dirt/dust caps in accordance with best industry practice; it is desirable that such closures conform to MIL-C-5501 (see 4.3.1.12.5 and 5.2).

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3.3.1.12.6 Test ports. Winch adjustment and troubleshooting shall be facilitated by the incorporation of hydraulic test ports or similar capabilities on all valves and the motor. Test ports on the baseline winch (for M88A2 PPQT test) are considered adequate (see 4.3.1.12.6).

3.3.1.13 Electrical components. All electrical components on the winch shall operate on 24 volts DC (nominal). Electrical switches, wiring and connectors shall be robust enough for operation in any of the types of operation, terrain conditions and ambient temperatures to which the M88A2 HERCULES is subjected in accordance with the provisions of ATPD 2150. Electrical components shall be waterproof and resistant to incidental contact with MIL-L-2105 multipurpose gear lubricating oil, MIL-H-46170, Type I, fire resistant hydraulic fluid, grease and vehicle fuels (JP8, Jet-A or DF2).

All sensors shall be mounted to permit the full range of adjustment (see 4.3.1.13).

3.3.1.14 Drum. The winch drum shall have Lebus type grooving. The drum diameter shall be at least 24.75 inches when measured at the bottom of the grooving. Cumulative third layer drum capacity should not be less than 315 feet of the intended use wire rope. Drum stiffness will be sufficient to prevent the development of any internal interference during operations in accordance with section 3.2.1 of this specification (see 4.3.1.14, 10.2, 10.2.1 and 10.2.2).

3.3.1.15 Lubricating oil. Oil conforming to SAE J2360, Lubricating Oil, Gear

Multipurpose Military Use, viscosity grade 80W-90 shall be used during factory fill, all winch testing, and after installation of the winch into the M88A2 HERCULES, when operating in ambient temperatures between -10 degrees F and 95 degrees F (-23 to 35 degrees C). In ambient temperatures continuously above 80 degrees F (27 degrees C), oil conforming to SAE J2360, viscosity grade 85W- 140 should be used. Oil conforming to SAE J2360, viscosity grade 75W, should be used when ambient temperatures are expected to be continuously below 10 degrees F (-12 degrees C) (see 4.3.1.15).

3.3.1.16 Seals. The winch, as appropriate, shall be equipped with seals to restrict the entrance of water and foreign matter during operations (vehicle or winch), including fording and steam/decontamination cleaning. Bearing seals shall restrict the leakage of lubricants from the bearings (see 4.3.1.16).

3.3.2 Shock, vibration, and electromagnetic radiation. The winch sensors/controls shall be mechanical or electrical (solid state). The capability to withstand shock, vibration, and electromagnetic radiation shall be in accordance with the guidelines and test methods of MIL-STD-810 and the requirements of MIL-STD-461 (see 4.3.2).

3.3.3 Painting, marking, and data plates.

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3.3.3.1 Painting. Winch parts, except as noted herein, shall be painted using High Solids Epoxy Coating, MIL-C-22750 and the procedures provided by the following drawings: aluminum surfaces, drawing 12369002; steel surfaces, drawing 12369004 and pretreated surfaces, drawing 12369023. Where components of the winch are procured by the winch manufacturer from outside sources and such components are commonly supplied by these sources in the painted condition, exception may be taken to the requirement for the pretreatment step. However, to reduce the risk of paint adhesion problems, it is desirable that such components be procured less the final top coat finish when and if possible. The winch manufacturer shall finish any such procured component per the requirements of drawings 12369002, 12369004 or 12369023, as applicable. The Government reserves the right to require pretreatment on such components when and if paint adhesion is determined to be a problem. External winch parts, except as noted herein, should be painted separately to improve corrosion resistance. All rollers and their associated moving parts shall be free to move after painting. All threads used for structural or hydraulic joining shall be free of paint prior to assembly; exposed external threads may be painted following assembly.

Plated hardware items such as bolts, screws, washers, nuts, and hydraulic fittings may be painted after final assembly. All hydraulic ports, the chain and the diamond screw mechanism shall be free of paint. The chain and diamond screw mechanism should be treated with light oil, for lubrication and preservation, instead of being painted. The outer port side surface of the cross port relief valve (opposite side from that containing the 0-ring groove) shall be free of paint. This surface on the cross port relief valve mates with hydraulic manifold P/N 12364943 and may be masked off during painting and for shipment (see 4.3.3.1).

3.3.3.2 Marking. The winch shall be marked in accordance with MIL-STD-130 (see 4.3.3.2).

3.3.3.3 Data plates. The winch shall be equipped with a photo-sensitive aluminum data plate, material Composition C, in accordance with MIL-P-514. The information on the data plate shall be presented using a character size not less than .11 inches in height. The data plate shall be installed on a flat surface of the winch frame, on the motor side. See drawing 12364530. The data plate, as a minimum, shall contain the following (see 4.3.3.3):

The original design activity CAGE code followed by “ASSY” and the original design activity item identification number. For the winch the following information shall be used: “19207ASSY12364530”

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The next line shall contain the abbreviation “MFR” followed by a dash symbol and the winch manufacturer’s CAGE code. For the winch, the following information serves as an example: “MFR - *”

The remaining information to be included on the data plate includes the following lines (which can be paraphrased to match the winch manufacturer’s standard terminology):

Item Nomenclature - Main Winch Assembly Main Winch Assembly Serial No. - * Date of Manufacture - * Contract Number - * Manufacturer - * Manufacturer’s Model Number - *

* To be provided by the winch manufacturer

3.3.4 Workmanship. Workmanship shall be of sufficient quality to assure a winch free of defects resulting from defective material and improper manufacturing or assembly practices. The level of quality shall assure the winch conforms to the requirements specified herein (see 4.3.4).

3.3.5 Parts interchangeability. Like units, assemblies, subassemblies and replacement components of the winch shall be physically and functionally interchangeable without modification of the items or equipment, except those components furnished as matched sets or for which a selection fit is specified. Individual winches shall not be hand-picked for fit or performance.

Reliance shall not be placed on any unspecified dimension or rating characteristic. No parts shall be altered or hand-fitted during assembly unless such modification has been authorized by an approved drawing change, or is authorized by instructions presently specified on the drawings (see 4.3.5).

3.3.6 Safety. The winch of itself shall have no catastrophic or critical hazards (CAT I or II) in accordance with MIL-STD-882, excluding catastrophic or critical hazards resulting from the integration of the winch subsystem (i.e., winch, wire rope and hydraulic connections) into the M88A2 HERCULES (see 4.3.6).

3.4 Personnel. The winch shall be capable of efficient and effective operation and maintenance by the properly trained Military Occupational Specialties (MOS): 63E and 63H (see 4.4).

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3.5 Order of precedence. In the event of a conflict between the text of this specification and the references cited herein (except for associated detail specifications, specification sheets or MS standards), the text of this specification shall take precedence. Nothing in this document, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained. All references to the M88A2 HERCULES in this specification refer to ATPD 2150.

4. QUALITY ASSURANCE PROVISIONS

4.1 General.

4.1.1 Quality assurance inspection articles. When specified (see 6.2), the contractor shall furnish winch assemblies, which shall be subjected to quality assurance inspections. Inspection samples, properly marked with identifying information, shall be representative of the equipment to be furnished to the Government. All subsequent equipment delivered to the Government shall conform to these samples in all of their pertinent physical and performance attributes.

4.1.2 Quality assurance terms. Unless otherwise specified, quality assurance terms used herein shall be as defined in ISO 8402.

4.1.3 Responsibility for inspection. Unless otherwise specified in the contract or purchase order

(see 6.2), the contractor is responsible for the performance of all the Quality Assurance Provisions specified herein (Section 4) to determine conformance with the requirements of Sections 3 and 5. Except as otherwise specified, the contractor may utilize their own facilities or any commercial laboratory acceptable to the Government. The Government reserves the right to perform or witness any of the inspections set forth in this document where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

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4.1.3.1 Responsibility for compliance. All items must meet all requirements of Sections 3 and 5.

The inspection set forth in this specification shall become a part of the contractor's inspection system or quality program for the subject winch. The absence of any inspection requirements in this specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection, as a part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to acceptance of defective material.

4.1.3.2 Inspection equipment. Unless otherwise specified in the contract or purchase order, the contractor is responsible for the provision and maintenance of all inspection and test equipment necessary to assure that supplies and services conform to contract requirements. Commercial, modified commercial or supplier designed inspection equipment or measuring setups must be capable of repetitive measurements to an accuracy of ten percent of the component tolerance.

Calibration of inspection and test equipment shall be in accordance with ISO 10012-1, except that the calibration recall date may be expressed as MM/YY.

4.1.3.3 Inspection records. Unless otherwise specified in the contract or purchase order, (see 6.2), quality documentation requirements not specified as a deliverable to the Government shall be maintained on file by the contractor and available for Government review at Government request. The contractor shall have a system for establishing and maintaining control of records documenting product compliance to applicable procurement documents, drawings, specifications and standards.

Records/documents shall be maintained to provide objective quality evidence of conformance to contract requirements. They shall be legible, provide traceability to specific products and use actual data, when required by applicable specifications, to indicate acceptability of the product. Records shall be maintained for a minimum of seven (7) years after final shipment. At the end of seven years the contractor must provide the Government the option of having the records forwarded to the Government for retention as required by the contract or authorizing disposal at the contractor's convenience.

Unless otherwise specified by the contract or purchase order, documentation of compliance to technical requirements for subcomponents of the delivered winch assembly shall be maintained on file for review by the Government. The Government retains the right to request any supporting documentation.

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4.1.3.4 Verification. All quality assurance operations performed by the contractor with respect to the winch shall be subject to the Government verification at unscheduled intervals. Verification shall consist of (a) surveillance of the operation to determine that practices, methods, and procedures of the written quality assurance system plan are being properly applied, (b) product inspection to measure the quality of the product offered for acceptance, and (c) testing identified in any individual detailed test plan. Deviation from the prescribed or agreed upon procedure or instances of poor practices which might have an adverse effect upon quality of the product, shall immediately be called to the attention of the contractor. Failure of the contractor to promptly correct deficiencies shall be cause for suspension of acceptance until corrective action has been made or until the conformance of the product to prescribed criteria has been demonstrated.

4.1.4 Inspection and test conditions. Unless otherwise specified in the contract or purchase order

(see 6.2) or herein, all inspections and tests shall be performed under the prevailing conditions of temperature, barometric pressure, and humidity at the test site and/or place of manufacture, not to exceed those environmental conditions defined in Table II. The wire rope used shall be per Drawing 12364546 (see 10.2).

4.1.4.1 Fluid leakage defects. The following shall be used in classification of fluid leakage defects:

a) Class I - Seepage of fluid (as indicated by wetness and discoloration) not great enough to form drops.

b) Class II - Leakage of fluid great enough to form drops but not great enough to cause drops to drip from item being checked/inspected.

c) Class III - Leakage of fluid great enough to form drops that fall from the item being checked/inspected.

4.1.4.2 Government operational testing. Government operational testing of the winches shall mean field testing of the winches while installed in the M88A2 HERCULES and subjected to the conditions, environments and user/maintainer skill levels consistent with that described in ATPD 2150. Government operational testing includes the winch durability cycles described in Section 4.5.1.

4.1.5 Special tests and examinations.

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

a. First article test (FAT) (see 4.1.3.2).

b. Component acceptance test (CAT) (see 4.1.3.3).

c. Quality Conformance Inspection (QCI) (see 4.1.3.4).

The requirements and methods of inspection for each inspection classification are identified in Table III. The "X" symbol indicates that compliance with the specific requirement shall be verified by testing and/or examination. The "C of C" symbol indicates that compliance with the specific requirement shall be certified by the contractor via the general "Certificate of Compliance."

4.1.5.2 First article test (FAT). When specified (see 6.2), first article test (FAT) shall be performed on a pre-production or initial production sample. Approval of the FAT sample by the Government shall not relieve the contractor of the obligation to supply winches or components that are fully representative of those inspected for FAT. Any changes or deviations affecting component fit, form or function/performance on the production units from that of the FAT sample shall be subject to the prior approval of the Government. The FAT sample shall consist of one winch. FAT shall be performed in accordance with Table III.

4.1.5.2.1 First article test failures. Deficiencies found during, or as the result of, the first article test shall be cause for rejection of the first article sample until evidence has been provided by the contractor that corrective action has been taken to eliminate the deficiency. Any deficiency found during, or as the result of the first article test shall be evidence that all items already produced prior to completion of the first article test are similarly deficient unless contrary evidence satisfactory to the Government is furnished by the contractor. Such deficiencies on all items shall be corrected by the contractor. The Government will not accept products until first article test is completed to the satisfaction of the Government.

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Table III. Classification of Inspection

Title Requirement Method FAT CAT QCI

Line Pull 3.2.1.1 4.2.1.1, 4.1.3.4 X X X(a) Loaded Line Speed 3.2.1.2.1 4.2.1.2.1 X C of C C of C Unloaded Line Speed 3.2.1.2.2 4.2.1.2.2 X X C of C Weight 3.2.2.1 4.2.2.1 X X Envelope 3.2.2.2 4.2.2.2 X X C of C Lifting Eye 3.2.2.3 4.2.2.3 X X C of C Interfaces 3.2.2.4 4.2.2.4 X X C of C Health 3.2.2.5 4.2.2.5 Durability 3.2.2.6 4.2.2.6 Reliability 3.2.3 4.2.3 Maintainability 3.2.4 4.2.4 Environmental 3.2.5 4.2.5 X Design and Construction 3.3 4.3 C of C Materials, Processes, and Parts 3.3.1 4.3.1 C of C C of C C of C

Material Deterioration Prevention and Control

3.3.1.1

4.3.1.1

C of C

Dissimilar Metals 3.3.1.2 4.3.1.2 C of C C of C C of C

Identification of Materials and Finishes

3.3.1.3

4.3.1.3

Qualified Products 3.3.1.4 4.3.1.4 C of C C of C C of C

Ozone Resistance 3.3.1.5 4.3.1.5 C of C C of C C of C

Hydraulic Fluid Compatibility 3.3.1.6 4.3.1.6 C of C C of C C of C

Winch Brake/Clutch 3.3.1.7 4.3.1.7, 4.1.3.4 X X X Spooling Roller 3.3.1.8 4.3.1.8 X X C of C Layer Sensor 3.3.1.9 4.3.1.9 X X X(a) End of Rope Sensor 3.3.1.10 4.3.1.10 X X C of C Diamond Screw 3.3.1.11 4.3.1.11 X X X

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Table III. Classification of Inspection (Continued)

Title Requirement Method FAT CAT QCI

Hydraulic Components 3.3.1.12 4.3.1.12 C of C C of C C of C Hydraulic Motor 3.3.1.12.1 4.3.1.12.1 C of C C of C C of C Counterbalance Valve 3.3.1.12.2 4.3.1.12.2 C of C C of C C of C Cross-Port Relief Valve 3.3.1.12.3 4.3.1.12.3 C of C C of C C of C Hydraulic Lines 3.3.1.12.4 4.3.1.12.4 X X X Hydraulic Cleanliness 3.3.1.12.5 4.3.1.12.5 X X X Test Ports 3.3.1.12.6 4.3.1.12.6 C of C C of C C of C Electrical Components 3.3.1.13 4.3.1.13 X C of C C of C Drum 3.3.1.14 4.3.1.14 X X C of C Lubricating Oil 3.3.1.15 4.3.1.15 C of C C of C C of C Seals 3.3.1.16 4.3.1.16 C of C Shock, Vibration, and Electromagnetic Radiation

3.3.2

4.3.2

X

Painting 3.3.3.1 4.3.3.1 X X C of C Marking 3.3.3.2 4.3.3.2 X X X Data Plates 3.3.3.3 4.3.3.3 X X X Workmanship 3.3.4 4.3.4 X X X

Parts Interchangeability 3.3.5 4.3.5 X Safety 3.3.6 4.3.6 Personnel 3.4 4.4 Preparation for Delivery 5. 4.5 X X X

(a) For the motor torque certification option, X in QCI becomes C of C.

4.1.5.3 Component acceptance test (CAT). When specified (See 6.2), the component acceptance test (CAT) shall be performed on a preproduction or initial production sample. Approval of the CAT sample by the Government shall not relieve the contractor of the obligation to supply winches or components that are fully representative of those inspected for CAT. Any changes or deviations of the production units from the CAT sample shall be subject to the prior approval of the Government. The CAT sample shall consist of one winch, and CAT shall be performed in accordance with Table III.

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4.1.5.3.1 Component acceptance test failures. Deficiencies found during, or as the result of, the CAT shall be cause for rejection of the CAT sample until evidence has been provided by the contractor that corrective action has been taken to eliminate the deficiency. Any deficiency found during, or as the result of the CAT shall be evidence that all items already produced prior to completion of the CAT are similarly deficient unless contrary evidence satisfactory to the Government is furnished by the contractor. Such deficiencies on all items shall be corrected by the contractor. The Government will not accept products until resolution of CAT failures is completed to the satisfaction of the Government.

4.1.5.4 Quality Conformance Inspection (QCI). Quality Conformance Inspection (QCI) shall be conducted on each winch assembly (100% inspection) in accordance with Table III.

4.1.5.4.1 Winch QCI test. The winch manufacturer shall perform initial adjustment of each winch prior to conducting any tests. The test shall consist of at least the following:

a) Operate the winch for a period of 15 minutes under a load of 2,000 pounds.

b) Apply 5 psi air pressure to the winch case and check for leakage.

There shall be no leakage.

c) The winch shall be subjected to a 140,000 pound single line pull on all layers. Motor displacement circuitry shall be adjusted to provide a line pull of 140,000 pounds +/-10% on all three layers, at stall, with 4200 psi supplied to the motor inlet and 100 psi applied to the motor outlet (delta p = 4100 psi), hydraulic oil temperature should be 100 deg. F +/-10 deg. F (viscosity of 18-13 centistokes with MIL-H-46170, Type I). It is desirable that the nominal line pull (at stall) of 140,000 pounds (+/-2500 lbs) on each layer be the target set point for factory adjustment to allow maximum use of the +/- 10% tolerance on installed winches.

Stall shall be achieved by inhauling an initially slack wire rope (see 10.2) anchored to a dead man until tight and 75% +/-2.5% of nominal pull is achieved (105,000 lbs desired). The winch control will then be placed in neutral for a one second minimum with this load imposed. The winch shall then be in-hauled again until the single line pull load is sufficient to prevent drum rotation (i.e., stall) and the load achieved at stall recorded. Stall must be between 126,000 and 154,000 pounds (137,500 to 142,500 lbs desired) on

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each layer. All adjustment screws shall be sealed or made "tamper proof" after setting. There shall be no fluid leakage or permanent deformation of the structural elements of the winch (see 4.1.2.1).

Following qualification of the design performance of the main winch in CAT and with approval from the Government, the contractor may substitute certification of the hydraulic motor torque for the line pull test/measurement on each layer. Approval from the Government shall not relieve the contractor from the responsibility to correct any mechanical, hydraulic or electrical deficiencies on winches certified via the motor torque, which subsequently produce stalls outside the 126,000 to 154,000 pounds range during final vehicle inspection prior to delivery to the Government.

d) The main winch brake shall be checked for release at a nominal pressure of 500 psi and for holding against a 154,000 pound line tension.

e) Operation of the one way clutch shall be verified by paying in the winch; there shall be no winch or hydraulic system chatter.

4.1.5.4.2 Winch QCI failures. Deficiencies found during, or as a result of QCI inspections and tests shall be cause for rejection of the production quantity represented until evidence has been provided by the contractor that corrective action necessary has been taken to eliminate the deficiency, prevent its recurrence, and the corrective actions taken have been approved by the Government. The Government will not accept products until quality conformance inspection is completed to the satisfaction of the Government.

4.2 Characteristics.

4.2.1 Performance inspection methods.

4.2.1.1 Line pull. To determine conformance to 3.2.1.1, the winch shall demonstrate the capacity for a 140,000 pound +10% single line pull. Stall shall be achieved by inhauling an initially slack wire rope anchored to a dead man until tight and approximately 75% of nominal pull is achieved (105,000 lbs desired). The winch control will then be placed in neutral for a one second minimum with this load imposed. The winch shall then be in-hauled again until stall occurs and the load achieved at stall recorded.