Attachment_2,_Sample_Test_Scenario.pdf

SCENARIO

Test Plan Concept for 5000 mile Follow-on Production Test (FPT)

Of a M1123

Objectives: Prepare a Detailed Test Plan (DTP) to conduct a 5000 mile FPT test of an Up-

Armored M1123 HMMWV in a tropical environment. A fictitious ADSS number of 2018-DT-

TRT-HMMWV-Q1234 is provided to utilize on the cover page of the DTP. The format for the

DTP is provided as a separate document for utilization by the bidders

The FPT at TRTC is scheduled for a 4-month period, 1 June August through 30 November

2018, and will be conducted utilizing one Up-Armored Vehicle Carrier, HMMWV M1114.

Criteria for the FPT will be derived from the Purchase Description, Army Tank Purchase

Description (ATPD) 2099E, dated 21 January 2009. An initial and final inspection will be performed on the vehicle upon arrival and on completion of testing. Jet propellant (JP)-8 fuel will be used for all endurance and performance operations. Note: ATPD is provided as a separate document.

Endurance testing will conducted to demonstrate reliability, availability, and maintainability (RAM) characteristics of the system. The 5,000 miles of endurance operations, with a 500-mile break-in period. Review ATPD for breakdown of mileage.

Vehicle performance testing will be performed prior to initiation of RAM testing.

Performance tests to be conducted are: Gradeability, Side Slopes, Vertical Step, Speed and

Acceleration, Braking, Road Load Cooling, and Towing a like vehicle. The selected FPT specifications (paragraphs) from the ATPD to be verified are 4.8.1 thru 4.8.7, 4.8.9, 4.8.10,

4.8.13. 4.8.14. 4.8.15, 4.8.16, 4.8.17.

The appropriate Test Operating Procedures (TOPs) shall be referenced in each subtest

Test Incident Reports (TIRs) will be prepared on all problems, failures, significant observations, and performance test results noted throughout the test period.

Observer Data Input Nexus (ODIN) will be used to collect all operational and maintenance data and VISION Digital Library System (VDLS) will be used to post the data. These data will be used for the overall analysis of the Up-Armored HMMWV M1123 vehicle and would be presented in the final report. Note: For purposes of this exercise no report is required.

Safety and health characteristics must monitored throughout the test program. Any serious safety hazards revealed will require immediate corrective action before testing will be allowed to proceed. All hazards noted will be classified in accordance with (IAW) Military

Standard (MIL-STD)-882D (or its most current version) and will be reported in TIRs.

Test Coordination

Things to consider but not limited to:

1. Describe how vehicle and support equipment will be shipped from Yuma Proving

Ground (YPG) to Tropic regions Test center (TRTC) in Panama.

2. Who will you coordinate with in Host Nation to allow for entry of vehicle?

3. What entities will be coordinated with in Host nation to allow for execution of test?

4. Will test be support by in-house TRTC personnel or will support be augmented by YTC.

5. If test support from YTC is required who will coordination be with?

6. How will vehicle be transported from port of entry to the test site. Note: Test will be conducted in the Horoko area with Cerro Tigre as a backup.

7. Describe how vehicle and support equipment will be returned to Yuma?

TEST PLAN FORMATS FOR DEVELOPMENTAL TESTS.

The test plan provides explicit instructions for the conduct of tests and subtests as instructed by the test directive. It governs test control, data collection, data analysis, and administrative aspects of test operations. The test plan should contain sufficient details to enable test repeatability, if necessary.

Test plans will be written for all test projects.

a. Detailed Test Plan (DTP) (DT Detailed Test Plan 090413). The DTP is the major planning document for the conduct of the Developmental Test for an acquisition evaluated system. A DTP may also be written for a non-evaluated or a non-acquisition project, if necessary. The test officer will prepare the DTP in accordance with the directions provided in the test directive.

b. Test Plan (TP) for Acquisition Non-evaluated Projects or Non-acquisition Projects (DT Test

Plan non-Evaluated 090413). The TP for an acquisition non-evaluated project or a non-acquisition project (DOD non-acquisition programs, US Federal Government Agency (non-DOD), commercial entity, academia, and Foreign Military Sales) may be provided by the customer or prepared by the test center at the request of the customer. To be responsive to the customer’s needs, these test plans should be tailored to include the minimum amount of information required to conduct the test.

c. Test Plan (TP) for Test Events or Test Records (DT Test Plan for test record 090413). If

ATEC is to provide a test plan for a non-evaluated or non-acquisition DT, this format may be used when the report will be a test record or event record. A cover page is not required for this type of test plan.

Month YYYY

Detailed Test Plan for the

(Name of Test/Evaluation)

Produced By

The US Army (Test Center)

Produced For

(PM or Customer, as appropriate)

DISTRIBUTION STATEMENT PER ATEC PAMPHLET 73-1, VOLUME II

The use of a trade name or the name of the manufacturer or a contractor in this report does not constitute an official endorsement or approval of the use of such commercial hardware or software or of service. The report may not be cited for purposes of advertisement.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure or reconstruction of the document.

This document contains information EXEMPT FROM MANDATORY DISCLOSURE under the Freedom of Information Act. Exemption 5 (predecisional materials) applies.

Place subordinate organization logo here.

Must be 90% reduction in size of

ATEC logo

AD No: (As appropriate)

ATEC Project No: (As appropriate)

(Name of principal author)

FRONT COVER

The outside front cover and the reverse of the front cover are prepared in accordance with administrative specifications.

The reverse of the front cover will contain the following information:

DISPOSITION INSTRUCTIONS

Destroy this document when no longer needed. Do not return to the originator.

The use of trade names in this document does not constitute an official endorsement or approval of the use of such commercial hardware or software. This document may not be cited for purposes of advertisement.

TABLE OF CONTENTS (Page i)

If the report is to contain hyperlinks, the following note will be included:

Note: To use hyperlink in this report, click on the blue, underlined text. To return to the previous position, click on the back arrow on the Adobe toolbar

(at the bottom of the page). The back arrow is not shown until after a hyperlink has been clicked.

This table of contents lists each major section and subtest heading of the test plan.

SECTION 1. INTRODUCTION

1.1 SYSTEM DESCRIPTION

The description is derived from the SEP, TEMP, or other source documents. It should describe the test item in terms of function, technical parameters, physical characteristics, mission, and threat. If the test item consists of several major components, identify these and describe each. If test items differ from previously tested items, describe the differences in the test items.

If literature on the test item exists, include appropriate extracts of the description and cite the reference. Ensure that the manufacturer’s performance claims are not included as facts in the description. Listing physical characteristics rather than performance information is advisable.

This description must permit full understanding of the item. Include a line drawing or photograph, if available.

1.2 SUMMARY

Briefly address the test authority, test concept, and test objective(s) in this paragraph. The test authority will be included in the test directive and referenced as an appendix. The test concept is a statement of the overall purpose of the testing actions. It is a general answer to the question “Why is the test effort being performed?”

The test objectives present an overview of the type of subtests and objectives. Cite sufficient detail to allow the reader to clearly understand the extent of testing. Address special test considerations required such as known limitations. The DSM in the SEP details those measures for which ATEC-AEC is responsible relative to the evaluation.

If there is no SEP or OTA TP, include general test concepts and design based on the scope of work.

An example of the summary is shown below:

The U.S. Army Test and Evaluation Command (ATEC) issued a Test Execution Directive to the U.S. Army Aberdeen Test Center (ATC), Aberdeen Proving Ground (APG), Maryland, to conduct a [insert type of test] on one [insert system name] (SN [insert serial number]) (ATEC Project No. [insert]). This [type of test] will examine [insert subtests]. Testing will be conducted from [insert test dates]. A summary of the test objectives is presented in Table 1.

TABLE 1. TEST OBJECTIVES

Subtest Objective

2.1 Initial Inspection To ensure that each item is undamaged, complete and ready for testing.

2.2 Test Item Control and

Data Management

To identify by test item the location in which they are to be distributed and distribute all the test items to the appropriate test facilities and field locations, and retrieve all independent laboratory test results and field data and consolidate them into a final report.

[insert subtest] [insert objective]

1.3 UNIQUE TEST PERSONNEL REQUIREMENTS

Describe the use of TSARC personnel in terms of critical operator and maintainer tasks or the need for Soldiers to conduct the test.

2.0 SUBTESTS

This is the most important section of the test plan. For acquisition-evaluated projects include specific subtests necessary to provide test data to answer the evaluator’s Critical Technical

Parameters and to verify compliance with contractual specifications.

State what is being measured and how the test will be accomplished. When appropriate, reference applicable elements from the SEP, OTA TP, or AEC test directive.

Keep the subtest limited in scope. In general, the criteria are the guide for subtest partitioning. A short subtest discussing only one specific topic is easier to write and read.

Longer subtests may be divided into supplements. Include such subtests as safety; performance;

vulnerability, ballistic survivability; logistic supportability, reliability; climatic suitability, durability; nuclear and electromagnetic survivability, transportability, and human engineering.

For subtests to be satisfied by contractor/developer testing that are described in a published contractor/developer test plan, for which the test manager has assigned certain responsibilities to the Test Center (e.g., data analysis, data reduction, or on-site monitoring), ensure that complete information on that subtest is provided. Describe all elements for that subtest from the externally prepared document and delineate the responsibilities of the Test Center.

Include sufficient detail to enable approving authorities to determine if the scope of the specific subtests will accomplish the subtest objective, to determine the justification for conducting the subtests, and to allow a tester other than the plan’s author to conduct the test.

2.1 NAME OF SUBTEST

2.1.1 OBJECTIVES

2.1.2 CRITERIA AND DATA ANALYSIS/PROCEDURE

State the criteria verbatim from their sources. State source and paragraph in parenthesis following each criterion. The criteria may be derived from the SEP, requirements documents, test directive, regulations, standards, and/or operating procedures.

When a portion of a listed criterion is not to be examined, underline the nonapplicable portion and add the following statement at the bottom of each page on which underlining is used:

Note: Underlined portion of criterion will not be addressed.

The criteria should be quantitative where possible, but qualitative criteria are acceptable if the circumstances do not lend themselves to numerical values. The criteria should be stated so they may be considered in terms of met, partially met, or not met.

For a subtest with no criteria available, the test director may develop criteria, listing the Test Center as the source. The approval of the test plan will constitute approval of the subtest criteria.

If no criteria would be required (i.e., subtest designed to provide data with no assessment), state “This subtest is conducted to document technical performance.”

A complete listing of criteria will be included in appendix A. In those cases when several criteria are listed, appendix A of the plan may be referenced in lieu of listing numerous criteria (e.g., “See items 2 through 10 and 17 in appendix A”).

Describe how the data are to be analyzed by the Test Center and how they should be reported. For each criterion, specifically identify in a separate subparagraph how it will be addressed and what condition will lead to a determination that the criterion has been met.

Address only that portion of a criterion applicable to the specific subtest.

Present the analytical procedure in the same order that it was introduced in the test procedure paragraph. Specify any compression, reduction, averaging, compilation, and/or statistical treatment. Include any assumptions that are appropriate.

For analytical and/or statistical procedures, the procedure should be identified in sufficient detail to allow another individual to carry out the analysis and to allow a reviewer (test manager, evaluator, PM, etc.) to judge the adequacy of the methodology. Sufficient detail does not mean the complete equations for computations such as a single T-test, standard analysis of variance (ANOVA), or simple point estimate, and confidence limits. Identification of statistical test name, sample size, confidence/or risk levels (whichever is appropriate), and any distribution assumption is sufficient. Analytical procedures should provide interpretations of criteria statements where necessary.

An example of the contents for this section is as follows:

2.1 FIELD DURABILITY AND PERFORMANCE TEST (FDPT)

2.1.1 Objective

The objective of this test is to subject the MBS system to use in U.S. Army field environments (including tropical, temperate, and cold climates) to determine the comfort, performance, compatibility and durability characteristics for multiple missions, terrains, and climates.

2.1.2 Criteria and Data Analysis

Data gathered during this test will be analyzed as presented in Table 2.1-1.

TABLE 2.1-1. CRITERIA AND DATA ANALYSIS

Criterion

(App A Item) Remarks/Analysis

11 - System Performance

If it is verified that the MBS is constructed of materials that can provide foot protection from environmental and climatic conditions/extremes, the criterion will be met.

12 - Weight Reduction

If the MBS achieves reductions in weight and a weight reduction of 5 percent over current boot(s) and components, the criterion will be met.

13 - Comfort, Mobility, and Traction

If it is verified that the MBS enhances Soldier’s comfort, mobility, and traction, the criterion will be met.

14 - Support If it is verified that the MBS is a lightweight (rugged), comfortable and supportive boot system designed for prolonged foot movement (road marches) while the Soldier carries heavy loads, normally designated as 120 lbs [maximum]), the criterion will be met.

2.1.3 TEST PROCEDURES AND DATA REQUIRED

The procedures to be used in the subtest should be described in sufficient detail to allow the reader to understand what will occur. If possible, TOPs, ITOPs, or MIL-STDs should be referenced. Describe in sufficient detail how the subtest will be conducted so that another individual knowledgeable in testing of such materiel could follow the procedure and conduct the test. Describe how the test item will be operated or what it will be exposed to in order to conduct the subtest.

Include a listing of all data elements that will be recorded during the subtest. Specify the accuracies (associated instrumentation tolerances) required for the measurements.

The use of standard forms, data sheets, or questionnaires is encouraged. If standard forms, data sheets, or questionnaires are to be used, include them as an appendix and reference that appendix.

An example of the Test Procedures and Data Required section is shown below:

2.1.3 Test Procedures and Data Required

a. General. Testing will be conducted at three separate U.S. Army locations to capture arctic, tropic, and temperate environment use for the MBS candidates. At each location, approximately 60 U.S. Army Soldiers (30 Soldiers for each of the two MBS candidates) will wear the MBS candidates for a 60-day period while conducting pre-planned garrison and field training operations. Additional trials with small groups of test participants will be conducted to focus on areas of donning, doffing, and compatibility of the (TOP) 10-2-021.

b. Test Conduct. The test team will conduct an in briefing, sizing/fitting, new equipment training (NET), and data collection training for all military test participants during the first day of testing at each location. The 60 test participants requested at each site to support the FDPT will be properly fitted with one MBS candidate by the test team.

(1) Demographic/anthropometric data. Demographic and anthropometric data will be collected on each test participant prior to test initiation.

(2) Fitting and issue. Each test participant will be fitted with one MBS candidate. The test participant will don the MBS and be asked to conduct walking and bending movements to assess the acceptability of fit.

c. The following data are required:

A complete listing of all test participants and associated TICN

Results of all demographic and anthropometric data for each test participant and associated percentile rankings

Results of all averaged don/doff time trials and narrative comments of any problem areas

Results of compatibility trials including photographs and narrative observations

Durability data including wear times, missions conducted, and issues of performance

All test incident reports (TIRs) including damage to the MBS test items documented through the Army Test Incident Reporting System (ATIRS)

SECTION 3. APPENDIXES

A. TEST CRITERIA

Extract appropriate test criteria verbatim from the SEP, requirements document, contract specification and standards, or other sources. This format will subsequently be used in the test report format with a “Remarks” column added. List as shown below:

Item Applicable

Source Test

Criteria Subtest Remarks

When a portion of a listed criterion is not to be examined, underline the nonapplicable portion and add the following statement at the bottom of each page on which underlining is used:

Note: Underlined portion of criterion will not be addressed.

B. TEST SCHEDULE

Provide realistic schedules of the test effort to ensure efficient programming and utilization of resources. Front load tests that provide input for the safety release.

Every effort should be made to minimize the time required to accomplish the test. Prepare an incremental test schedule presenting an estimate of net testing time similar to the one in figure E-

2.

C. INFORMAL COORDINATION

Informal coordination is that coordination effected with a PM or MSC. Include a list of all agencies with which the draft test plan was informally coordinated. Indicate coordination comments not incorporated into the plan. List the agency providing the comment, the comment, and the reason for not accommodating the comment. Major disagreements or anomalies, in the judgment of the test plan preparer, will immediately be brought to the attention of the AEC test manager.

D. REFERENCES

This appendix should list all documents mentioned in the plan, in the order in which they were mentioned.

E. ABBREVIATIONS

All acronyms, brevity codes, short titles, and abbreviations used in the plan are listed alphabetically with an explanation of their meaning. Do not list commonly used terms.

F. DISTRIBUTION LIST

The distribution list will list all agencies receiving the plan in accordance with the AEC test directive and internal Test Center requirements. All published and distributed technical reports, including ATEC’s final test report, must be provided to the Defense Technical Information

Center (DTIC) according to DoD/DA requirements.

Comments, suggestions, or questions on this document should be addressed to U.S. Army Tank-automotive and Armaments Command, ATTN: AMSRD-TAR-E/CM/DM/STND MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or emailed to dami_standardization@conus.army.mil.

Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http://assist.daps.dla.mil.

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

INCH-POUND

ATPD-2099E

21 January 2009

PURCHASE DESCRIPTION

HIGH MOBILITY MULTIPURPOSE WHEELED VECHICLE

(HMMWV)

This specification is approved for use by the U.S. Army Tank-automotive and Armaments Command and is available for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This system specification identifies the physical, performance and inspection requirements for the A2 series and Expanded Capacity Vehicle (ECV) series of the High Mobility Multi-Purpose Wheeled Vehicles (HMMWV). Unless otherwise noted in this specification, the M1123 variant shall be included as part of the A2 series of vehicles. Also the M1151/M1152/M1165/M1167 shall be included as part of the ECV series of vehicles. In simple terms, the M1151 has the body of the M1025A2 and placed onto the chassis of the ECV; the M1152 has the body of the M1097A2 (2-man version) placed onto the chassis of the ECV; the M1165 has the body of the M1097A2 (4-man version) placed onto the chassis of the ECV; and the M1167 is the TOW/ITAS variant based off of the M1151. (See Addendum in rear.) The system specification establishes these requirements by identifying the following:

a. Technical data requirements from which the vehicle is to be produced.

b. Physical characteristics and performance requirements for the vehicles produced.

c. Identification of the performance and quality test requirements used to verify the vehicles meet the specified performance standards.

The technical data package provided as part of this system specification identifies specifications and installations at a component level. The TDP does not identify the performance requirements of the final assemblage of these components at the system level. The physical characteristics and performance requirements are identified by this specification. Therefore, this specification shall form the basis for establishing and evaluating the vehicle's physical characteristics and performance.

1.2 General Description. The A2 vehicles represent the third stage of HMMWV evolution. The ECV vehicles represent the fourth stage of HMMWV evolution. Like the basic HMMWV and A1 series, the A2 and ECV vehicles are comprised of many common components. The various models are defined by different body configurations designed to meet

ATPD 2099E

particular mission roles. These roles include transport of materials, weapon systems, equipment, and personnel. While operating in these roles the vehicles are operated on primary and secondary roads, trails and off road terrain. The vehicles are also capable of fording water and operation in temperatures ranging from Basic Cold to Basic Hot conditions. With application of kits, the vehicles are also capable of arctic operation and deep water fording. Some major changes for the A2 and ECV vehicles include:

1. 6.5 Liter Engine (Turbo for ECV)

2. 4L80 Electronic Transmission

3. New Radiator

4. New Exhaust w/Catalytic Converter

5. Central Tire Inflation System Ready

6. Improved Air Cleaner

7. Dual Voltage Electrical System

8. Improved Collapsible Steering Column

9. Relocated Driver's Mirror

10. Higher Capacity Cargo Bed Tiedowns

11. Sun Visors

12. Improved Heater System

13. 3-1/2 Ton Jack

14. Improved Rear Seats

15. 10,500 Pound Hydraulic Winch Kit

16. Swing away oil cooler

17. Improved corrosion resistance

18. Reliability Enhancements

1.3 Vehicle Variants. The A2 and ECV vehicle variants are described as follows:

Model Number Nomenclature M997 A2 Truck, Ambulance, 4 Litters, Basic Armor M1025 A2 Truck, Utility, Armament Carrier, Basic Armor M1035 A2 Truck, Ambulance, 2 Litters, Soft Top M1043 A2 Truck, Utility, Armament Carrier, Supplemental Armor M1045 A2 Truck, Utility, TOW Carrier, Supplemental Armor M1097 A2 Truck, Utility, Heavy Variant M1123 Truck, Utility, Heavy Variant M1113 Truck, Utility, Expanded Capacity M1114 Truck, Utility, Expanded Capacity, Up-Armored, Armament

Carrier M1151 Truck, Utility, Expanded Capacity, Armament Carrier, 11,500 GVW, Base with AC M1151A1 Truck, Utility, Expanded Capacity, Armament Carrier, IAP/Armor Ready, 12,100 GVW

M1151A1 w/B1 Kit Truck, Utility, Interim Armored, Armament Carrier, 12,100 GVW, IAP W/B1 Armor Kit

M1152 Truck, Utility, Expanded Capacity, Enhanced, 11,500 GVW, Base with AC

M1152A1 Truck, Utility, Expanded Capacity, Enhanced, IAP/Armor Ready, 12,100 GVW

M1152A1 w/B2 Kit Truck, Utility, Interim Armored, Enhanced, 12,100 GVW, IAP W/B2 Armor Kit

M1165 Truck, Utility, Command and Control / General Purpose Vehicle, 11,500 GVW, Base with AC

M1165A1 Truck, Utility, Command and Control / General Purpose Vehicle, IAP/Armor Ready, 12,100 GVW

M1165A1 w/B3 Kit Truck, Utility, Interim Armored, Command and Control / General Purpose Vehicle, 12,100 GVW, IAP W/B3 Armor Kit

M1167 Truck, Utility, TOW Carrier, Armored, 13,100 GVW, IAP W/B1 Armor Kit

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 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 cited in the solicitation or contract.

INTERNATIONAL STANDARDIZAITON AGREEMENTS

STANAG 2040 - Stretchers, Bearing Brackets and Attachment Supports

(Copies of these documents are available from http://nsa.nato.int or from NATO Standardization Agency (NSA), North Atlantic Treaty Organization, HQ, 1110 Brussels, Belgium.)

COMERCIAL ITEM DISCRIPTION

A-A-50271 - Plate, Identification A-A-52557 - Fuel Oil, Diesel, for Posts, Camps, and Stations http://nsa.nato.int/

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-DTL-46593 - Projectile, Calibers .22, .30, .50 and 20 mm Fragment -

Simulating MIL-DTL-53072 - Chemical Agent Resistant Coating (CARC) System

Application Procedure and Quality Control Inspection MIL-DTL-83133 - Turbine Fuel, Aviation, Grades JP-8 , JP-5 MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service MIL-PRF-10924 - Grease, Automotive and Artillery MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic

DEPARTMENT OF DEFENSE STANDARDARDS

MIL-STD-193 - Painting Procedures and Markings for Vehicles, Construction and Material Handling Equipment MIL-STD-209G - Lifting and TieDown Provisions MIL-STD-461D - Requirements for the Control of Electromagnetic

Interference Emissions and Susceptibility MIL-STD-642 - Identification Marking of Combat and Tactical

Transport Vehicles MIL-STD-662 - V-50 Ballistic Test for Armor MIL-STD-810 - Environmental Engineering Considerations and

Laboratory Tests MIL-STD-814 - Requirement for Tiedown, Suspension and Extraction

Provisions on Military Material for Airdrop MIL-STD-889 - Dissimilar Metals MIL-STD-1180 - Safety Standards for Military Ground Vehicles MIL-STD-1261 - Arc Welding Procedures for Construction Steels MIL-STD-1366 - Interface Standard for Transportability Criteria MIL-STD-1472 - Human Engineering of Defense Design Criteria

Standards MIL-STD-1474B - Noise Limits MIL-STD-3003 - Vehicles, Wheeled: Preparation for Shipment and

Storage of

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-310 - Global Climatic Data for Developing Military Products MIL-HDBK-669 - Loading Environment and Related Requirements for

Platform Rigged Airdrop Material MIL-HDBK-759 - Human Engineering Design Guidelines MIL-HDBK-1223 - Non-tactical Wheeled Vehicles Treatment, Painting, Identification Marking and Data Plate Standards

MIL-HDBK-1791 - Designing for Internal Aerial Delivery in Fixed Wing Aircraft

(Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

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

US ARMY TECHNICAL MANUALS

TM-9-2320-280-10 - HMMWV Operator's Manual TM-9-2320-280-20 - HMMWV Technical Manual

(Copies of the above drawings are available from the U.S. Army Tank-automotive and Armaments Command, ATTN: AMSRD-TAR-E/CM/DM/STND MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000, or email DAMI_STANDARDIZATION@conus.army.mil.)

TACOM DRAWINGS

12340789 - Accessory and Supplementary Kit List 12460153 - Final Inspection Record 12472301 - Ground Combat Vehicle Welding Code – Alum.

12479197 - M1151, Truck, Utility, Expanded Capacity, Armament Carrier, Base w/AC 12479198 - M1152, Truck, Utility, Expanded Capacity, Enhanced, 11,500

GVW, Base with AC 12479550 - Arc Welding Procedures for Constructional Steels 13226E7102 - Cargo/Troop Carrier Camouflage Pattern 13226E7106 - Four Litter Ambulance Camouflage Pattern 13226E7108 - Weapon Carrier Camouflage Pattern 8750309 - M1025 A2, Truck, Utility, Armament Carrier, Basic Armor 8750310 - M1043 A2, Truck, Utility, Armament Carrier, Supplemental

Armor 8750311 - M1045 A2, Truck, Utility, TOW Carrier, Supplemental Armor 8750312 - M1035 A2, Truck, Ambulance, 2 Litters, Soft Top 8750314 - M997 A2, Truck, Ambulance, 4 Litters, Basic Armor 8750315 - M1097 A2, Truck, Utility, Heavy Variant 87T0014 - M1113, Truck, Utility, Expanded Capacity 87T0080 - M1123, Truck, Utility, Heavy Variant 87T0015 - M1114, Truck, Utility, Expanded Capacity, Up-Armored, Armament Carrier mailto:DAMI_STANDARDIZATION@conus.army.mil

87T0145 - Truck, Utility: Expanded Capacity, Armament Carrier 87T0146 - Truck, Utility: Expanded Capacity Enhanced, 11,500 Lb GVW 87T0147 - Truck, Utility: Command and Control General Purpose Vehicle 87T0148 - Truck, Utility: Command and Control General Purpose Vehicle 87T0174 - Truck, Utility: Expanded Capacity, Armament Carrier

13194972 - Transversing Unit 13195325 - Launcher, Tubular, Guided Missile: M220E3 13195325-0408 - Launcher, Tubular, Guided Missile: M220A4 13480670-1 thru -4 - Improved Target Acquisition System (ITAS)

(Copies of the above drawings are available from http://www.edis.redstone.army.mil/ or the U.S.

Army Tank-automotive and Armaments Command, ATTN: AMSRD-TAR-E/CM/DM/STND MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000, or email DAMI_STANDARDIZATION@conus.army.mil.)

AMCOM DRAWINGS

13582782 - Traversing Unit (TU) for ITAS

(Copies of the above drawings are available from http://www.edis.redstone.army.mil/ or the US Army Aviation and Missile Command – AMCOM, Attn: AMSAM-CIO-E-A, Building 4722, Rideout Road, Redstone Arsenal, Al 35898-5000, or e-mail

EDM-MEDALS@REDSTONE.ARMY.MIL)

DEPARTMENT OF TRANSPORTATION

Department of Transportation Regulations (part 325) Federal Motor Carrier Safety Regulations

(Copies of these documents are available from the Superintendent of Documents, U.S.

Government Printing Office, 710 North Capitol Street, NW, Washington, DC 20402, or at www.dot.gov)

AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGIENISTS

Threshold Limit Values for Chemical Substances in Work Air

(Copies of this document are available from ACGIH, 1330 Kemper Meadow Dr., Suite 600, Cincinnati, OH 45240, or at www.acgih.org).

http://www.edis.redstone.army.mil/ mailto:DAMI_STANDARDIZATION@conus.army.mil http://www.edis.redstone.army.mil/ mailto:EDM%1EMEDALS@REDSTONE.ARMY.MIL http://www.dol.gov/ http://www.acgih.org/

FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS)

(Compliance with FMVSS requirements shall be as specified herein and in MIL-STD-1180.

Copies of these documents are available from the Dept. of Transportation, Federal Highway Administration, Washington, D.C. 20591, or at http://www.gpoaccess.gov/cfr/index.html).

ENVIRONMENTAL PROTECTION AGENCY

Control of Air Pollution from New Motor Vehicles and New Motor Vehicle Engines.

(Copies of this document are available from the US EPA Headquarters, 401 M Street SW, mail code 3204, Washington, DC 20460 or at http://www.epa.gov).

TACOM

TACOM Design Guidelines for Prevention of Corrosion in Combat and Tactical Vehicles

Failure Definition and Scoring Criteria, HMMWV, Block II Detailed Test Plan, TECOM Project No. 1-VG-120-HMV-079

2.3 Non-Government Documents. The Following documents form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents shall be the issues in effect on the date of Request for Proposal.

ASTM INTERNATIONAL

ASTM D1149 - Rubber Deterioration-Surface Ozone Cracking in a Chamber

ASTM D2000 - Rubber Products in Automotive Applications

(Copies of these documents are available from the ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, or ordered online at www.astm.org).

SAE INTERNATIONAL

SAE J1100 - Motor Vehicle Dimensions SAE J2360 - Oil, Lubricating, Gear Multipurpose (Metric) Military Use http://www.epa.gov/ www.astm.org

(Copies of these documents are available from the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096-0001, or at www.sae.org).

2.4 Order of Precedence. The following order of precedence shall be applicable in the event of conflict between the requirements of the Contract, this specification and the documents referenced therein:

1. Contract Document

2. ATPD 2099E

3. The Technical Data Package

4. Government standards, specifications or handbooks

5. Non-government standards, specifications or handbooks

2.4.1 Compliance with Laws and Regulations. The requirements and specifications contained in the above documents shall not be interpreted as a waiver or allowance to supersede any law or regulation unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Mission Profile. The mission profile for all variants is comprised of 30 percent primary roads, 30 percent secondary roads and 40 percent off road operation. Reliability, maintainability and durability requirements specified herein shall be based on this apportionment and a total accumulation of 20,000 vehicle miles. The mission profile and required mileage breakdown shall be as shown in Table I.

TABLE I. Mission Profile.

Mission Profile Mileage 30% Primary Roads 6,000

30% Secondary Roads 6,000 40% Cross Country 8,000

Total Mileage 20,000

3.1.2 Vehicle Weights. Vehicle weights shall be in accordance with Table II.

TABLE II. Vehicle Weights.

Vehicle Model Curb Weight Gross Vehicle Weight

(GVW)

Gross Combined Weight (GCW)

M997 A2 7,660 10,300 14,080 M1025 A2 6,780 10,300 14,080 M1035 A2 6,100 10,300 14,080 M1043 A2 7,230 10,300 14,080 M1045 A2 7,258 10,300 14,080 M1097 A2 5,900 10,300 14,080 http://www.sae.org/

TABLE II. Vehicle Weights - Continued.

Vehicle Model Curb Weight Gross Vehicle Weight

(GVW)

Gross Combined Weight (GCW)

M1123 5,900 10,300 14,080 M1113 6,400 11,500 15,280 M1114 9,800 12,100 15,880 M1151 7,500 11,500 15,280

M1151A1 8,150 12,100 15,880 M1151A1w/B1 Kit 10,300 12,100 14,080

M1152 6,400 11,500 15,280 M1152A1 7,100 12,100 15,880

M1152A1w/B2 Kit 8,760 12,100 15,880 M1165 6,500 11,500 15,280

M1165A1 7,230 12,100 15,880 M1165A1w/B3 Kit 9,870 12,100 15,880

M1167 11,680 13,100 16,880

3.1.3 Curb Weight. Curb weight of the vehicle shall be defined as the weight of the vehicle, on vehicle equipment and full compliment of fuels, fluids and lubricants.

3.1.4 Gross Vehicle Weight. Gross vehicle weight shall be the curb weight plus the vehicle payload as defined in 6.7.

3.1.5 Gross Combined Weight. Gross combined weight shall be defined as the gross vehicle weight plus the weight of the towed load minus pintle weight.

3.2 Reliability. The A2 series of vehicles shall demonstrate a reliability point estimate of 1,425 Mean Miles Between Failure (MMBF), the ECV series of vehicles shall demonstrate a reliability point estimate of 1,170 Mean Miles Between Failure (MMBF). Both series shall demonstrate a reliability point estimate of 970 Mean Miles between Operational Mission Failure (MMBOMF). Vehicle reliability characteristics shall be calculated after completion of 20,000 miles operation in accordance with Table I. Data for unscheduled maintenance actions and mission failures shall be assessed and scored using the Failure Definitions/Scoring Criteria contained in the HMMWV, Block II Detailed Test Plan, TECOM Project No. 1-VG-120-HMV-079. The results of the scoring conference assessment will be used as the basis of compliance with the reliability requirements.

3.3 Maintainability. Vehicle maintainability characteristics shall be calculated after completion of 20,000 miles operation in accordance with Table I.

3.3.1 Maintenance Ratio. Maintenance Ratio (MR) is defined as the ratio of maintenance man-hours to engine operating hours. Maintenance man hours shall include the time required for all scheduled and unscheduled maintenance actions during the 20,000 miles of operation. The time required for daily crew checks and services will not be included in the maintenance ratio. The maintenance ratio shall be in accordance with Table III.

TABLE III. Maintenance Ratio.

Overall DS/GS Organ/Crew A2 Series 0 - 0.250 0.080 0.170 ECV Series 0 - 0.313 0.100 0.212

* Direct Support/General Support ** Organizational/Crew

3.3.2 Ease of Maintenance. Chassis components shall have direct and unrestricted access for inspection, servicing, repair and replacement. Maintenance provisions shall incorporate features insuring operating clearances and facilitate maintenance and service operations. There shall be an 0.80 probability that all pre-operational, during, and after operational vehicle checks, will be accomplished by operator/crew in 10 man minutes or less for all A2 series body styles and 15 man minutes or less for all ECV series body styles using On Vehicle Equipment (OVE) only.

3.3.3 Engine Accessibility. The vehicle shall have a 0.90 probability that the time required for removal and reinstalling the engine and transmission assembly shall be less than 10 man-hours for all A2 series body styles and less than 15 man hours for all ECV series body styles. Removal and reinstallation time is with all tools and parts readily accessible at the work site. Removal and reinstallation time shall not include time to remove and reinstall pre-equipment condition components.

3.3.4 Mean Time to Repair. The mean time to repair (MTTR) shall not be greater than

2.0 hours for any body style. Mean time to repair shall be defined as total actual maintenance clock hours divided by the total number of unscheduled maintenance actions.

3.3.5 Engine and Powertrain Durability. All body styles shall demonstrate a 0.5 probability of completing the 20,000 miles (32,187 km) of operation without replacement or overhaul of the engine, transmission, transfer case, differential.

3.4. (RESERVED)

3.5 General Specifications. Materials, components and their assembly and installation shall be as specified in the Technical Data Package. Material shall be free of all defects and imperfections that might affect the serviceability and function of the finished product. Material not specified shall be selected by the Contractor and shall be compatible with commercial engineering standards of the automotive and truck equipment industries. Selection shall also be commensurate with the intended end use and maintain the system performance and characteristics contained in this vehicle specification. In the event changes are required to the vehicle configuration, extensive effort shall be made to maintain commonality of components among the different vehicle models.

3.5.1 Fungus Resistance. Fungus resistance requirements shall be as identified on the drawings. In the event component or material changes are required, existing fungus resistance requirements shall be maintained as a minimum.

3.5.2 Rubber Components.

3.5.2.1 Rubber components shall be as specified on the drawings. In the event material or component changes are required the replacement or addition of rubber products shall be in accordance with 3.5.2.2, 3.5.2.3, 3.5.2.4 and 3.5.2.5.

3.5.2.2 Fuels and Lubricants. Components which will be in contact with fuels shall be compatible with and intended for use in contact with the fuels and lubricants identified in 3.5.8.

3.5.2.3 Low Temperatures. Rubber components which are subject to flexing, compression, tension or otherwise subjected to movement or change in shape shall satisfy the F-19 low temperature requirement as specified in ASTM D2000, except test temperature shall be -50 °F (-45.6 °C). All other rubber products not included in the above definition shall meet the F-17 low temperature requirement as specified in ASTM D2000.

3.5.2.4 Ozone Resistance. Exposed rubber components shall evidence no cracking after 72 hours of exposure in an ozone chamber per ASTM D1149, using Type B specimens with the ozone partial pressure maintained at 50 MPa.

3.5.2.5 Recycled, Virgin and Reclaimed Materials. All material shall be new and unused. Approved recycled material is acceptable when processed to make new material. When processing used or recycled polymeric materials, up to 20% regrind may be added to virgin materials.

3.5.3 Ozone Depleting Substances. No ozone depleting substances shall be used in the manufacture or the assembly of the vehicle.

3.5.4 Dissimilar Metals. Dissimilar metals shall be electrically insulated from one another in accordance with MIL-STD-889.

3.5.5 Corrosion Control. The vehicle has been designed for a total service life of 15 years which includes varying or extended periods in corrosive environments. These corrosive environments include high humidity, salt spray, road deicing agents, gravel impingement and atmospheric contamination. Current corrosion control techniques are compatible with Nuclear, Biological and Chemical (NBC) decontamination procedures. In the event a configuration, material or component change is required, such capability shall be maintained by a combination of design features (as found in but not limited to the TACOM Design Guidelines for Prevention of Corrosion in Combat and Tactical Vehicles), material selection (i.e. composites), production techniques, process controls, inspection and documentation. No action beyond normal washing, periodic inspection and repair of damaged areas shall be necessary to keep the corrosion protection in effect. Damaged areas are defined to mean any fault that is not a result of a deficiency in design, material, workmanship or manufacturing.

3.5.6 Finishing and Marking.

3.5.6.1 Painting. All vehicles shall be finished or painted to provide a low reflectance surface. The vehicle body and components shall be cleaned, treated, and painted in accordance with the TDP and MIL-STD-193. Chemical agent resistant coatings (CARC) systems, application procedures shall be in accordance with MIL-DTL-53072. In the event of a conflict between MIL-STD-193 and MIL-DTL-53072 the latter shall take precedence.

3.5.6.2 Camouflage Pattern. The vehicles shall be painted with the three color camouflage pattern as identified below:

MODEL DRAWING

M997 A2 13226E7106 M1025 A2 13226E7108 M1035 A2 13228E1658 M1043 A2 13226E7108 M1045 A2 13226E7108 M1097 A2 13226E7102 M1113 13226E7102 M1114 13226E7108 M1123 13226E7102 M1151 13226E7108 M1151A1 13226E7108 M1151A1w/B1 Kit 13226E7108 M1152 13226E7102 M1152A1 13226E7102 M1152A1w/B2 Kit 13226E7102 M1165 13226E7102 M1165A1 13226E7102 M1165A1w/B3 Kit 13226E7102 M1167 13226E7108

3.5.6.3 Marking. Vehicle exterior markings shall be placed and sized in accordance with MIL-STD-642, except "U.S. Army" ("USMC" or "USAF") in 3 inch (7.62 cm) high letters shall be used where the 5 point star is specified. All vehicle markings shall be non-reflective.

3.5.7 Data Plates. All data plates, decals and safety related markings furnished with the vehicle shall be in accordance with MIL-HDBK-1223 and A-A-50271, composition C Type I Style I for identification plates and Type III (style not applicable) for all others. The size of the plates shall not exceed the surface on which they are mounted.

3.5.8 Fuels and Lubricants. In addition to the component manufacturers specification, the vehicles shall be capable of operation using the fuels and lubricants identified in Table IV without adverse impact on performance or reliability. Fuels and lubricant applicability shall be as shown in the HMMWV technical manuals TM 9-2320-280-20-1 and TM 9-2320-280-10.

TABLE IV. Fuels and Lubricants.

Fuels Lubricants A-A-52557, Grade DF-A MIL-PRF-2104 A-A-52557, Grade DF-1 SAE J2360 A-A-52557, Grade DF-2 MIL-PRF-46167

MIL-DTL-5624, JP-5 MIL-PRF-10924

MIL-DTL-83133, JP-8 Dextron VI

3.5.9 Welding. Unless otherwise specified by the TDP:

a. All arc welding of steels shall be in accordance with drawing 12479550.

b. All welding of aluminum shall be in accordance with drawing 12472301.

3.5.10 Environmental.

3.5.10.1 Climatic Operational Conditions. The vehicle and its components shall withstand and operate under climatic condition design types "hot", "basic", and "cold" as defined by MIL-HDBK-310.

3.5.10.2 Climatic Operating Conditions. The vehicle, without any kit, shall start and operate within 10 minutes in a safe manner in ambient temperatures from –25 °F to +32 °F (-31.7 °C to 0 °C) and within 3 minutes in ambient temperatures from +33 °F to +120 °F (0.55 °C to 48.9 °C) in all altitudes from -500 feet (-152.4 m) through +1200 feet (366 m).

3.5.10.3 Climatic Design Type Cold. The vehicle, with arctic lubricants, coolants and kits, shall start within 45 minutes and be completely operable within 15 minutes after starting in ambient temperatures of -50 °F. Temperature shall be recorded 4 to 6 feet above ground level.

3.5.11 Production Qualification Test. When required by the Contract or order Production Qualification Testing shall be conducted in accordance with 4.4.

3.5.12 Secure Lighting. Light emissions shall be predominately in the visible spectrum (380 to 700 nanometers) for all lamps which can be illuminated in the blackout mode, with the exception of the blackout driving lamp. Emission peaks in the 700 to 1100 nanometer spectrum shall not exceed 1% of the peak emission in the visible spectrum.

3.5.13 Rail Impact. The vehicles at GVW shall meet the requirements of the American Association of Railroad Rail Impact Test and MIL-STD-810 Method 516.4 Procedure 8.

3.5.14 Cargo Tiedowns. Vehicles shall be equipped with cargo area tiedowns as identified in the Technical Data Package (TDP). Tiedowns shall meet the requirements of MIL-STD-209G except paragraph 5.1.4. The rated load of each tiedown location shall be 2500 pounds.

3.5.15 Electromagnetic Radiation. Except for the horn, the vehicle shall conform to the electromagnetic interference characteristics requirements for tactical equipment as prescribed in MIL-STD-461D Methods RE102, CS114, RS103, CE102 and CS101. RE and RS requirements are intended for the vehicle while the CS and CE requirements are for the component level.

3.5.16 DS2 Decontamination. The vehicle shall be capable of being decontaminated with DS2 decontaminating solution.

3.5.17 Transportability. The vehicles shall be transportable by highway, rail, marine, and air modes worldwide. Transportability criterion shall be as set forth in MIL-STD-209G, MIL-STD-1366, and MIL-HDBK-1791. Preparation for all modes of transportation and subsequent operation shall be accomplishable by two persons, one of which is a 5th percentile female. Preparation time for transport and subsequent preparation for operation shall not exceed 15 minutes each. Preparations for transportation and subsequent vehicle operation shall be accomplished using authorized Basic Issue Items (BII) and Additional Authorized List (AAL) items. All parts required to be removed and subsequently replaced shall have a place for stowage on the vehicle from which removed.

3.5.17.1 Helicopter Transport. All vehicle models, at rated GVW less the weight of personnel, shall be externally transportable by the CH-47 C & D, and the CH-53 D & E helicopters. Vehicles shall be externally transportable by the UH-60 within the performance envelope of the aircraft. The vehicle sling provisions shall comply with the design and performance criteria specified in MIL-STD-209G.

3.5.17.2 Air Transportability. The vehicle at rated GVW less the weight of personnel, shall be transportable by C5A, C141E, and C130 aircraft. The vehicles and cargo payloads carried by the vehicles during the air transport shall be equipped with tiedown provisions that meet the restraint criteria specified in MIL-HDBK-1791, and MIL-STD-209G.

3.5.17.3 Airdrop. The vehicle at rated GVW less the weight of personnel, shall be air-droppable in accordance with MIL-HDBK-669, MIL-STD-814, and MIL-HDBK-1791. Airdrop requirements are not applicable to the M997 A2 Ambulance. Airdrop requirements for the M1097 A2 and M1152 shall apply without the shelter installed.

3.5.18 Communications equipment. Provisions for mounting of the AN/GRC-160, TSEK/KY-57, C-2298/VRC, AM-1780/VRC and AN/VIC-1 communications equipment shall be maintained.

3.5.19…