AMENDMENT_1_and_SOW_Attachment.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

SEE PAGE 2 - Revised Statement of Work (SOW)

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 23-Aug-2018

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W911KF18Q0082

X 9B. DATED (SEE ITEM 11)

16-Aug-2018

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer is extended, X is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

23-Aug-2018

CODE

ARMY CONTRACTING COMMAND - WARREN (ANAD)

ANNISTON ARMY DEPOT

7 FRANKFORD AVENUE, BLDG 35

ANNISTON AL 36201-4199

W911KF 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W911KF18Q0082

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

The following items are applicable to this modification:

AMENDMENT NARRATIVE

1. The purpose of this amendment is to provide the loction for the Q&A deadline and revise the Statement of Work (SOW) and incorporate the following:

A. The final deadline for submitting questions and answers is located at the top of the

Narrative, “Inquiry regarding this solicitation will be accepted through 7 September 2018. A response will not be received for inquiry submissions after this date”.

B. The SOW has been revised to change the reference from 3.15 to 4.15 in those sections.

* 4.3

* 4.5.2

* 4.5.3

* 4.6.1

* 4.7.1

* 4.7.3

* 4.12.7.b

C. Section 7.1.1 of the SOW has been updated to reference the correct transmissions, the Allison XT‐1410‐4 and XT‐1410‐5A.

2. All other terms and conditions remain unchanged.

REVISED 20 Aug 2018

DESCRIPTION/WORK STATEMENT/SPECIFICATION

1. Scope. This specification establishes the requirement for one (1) cross-drive transmission test stand hereafter referred to as the “Equipment,” “Test Stand” and “machine”, to be provided to Anniston Army Depot, Anniston, Alabama. The intended application is for final acceptance testing of Allison XT-1410-4 and XT-1410-5A transmissions per the applicable National Maintenance Work Requirement (NMWR), NMWR 9-2520-215. The Equipment shall be designed and fabricated by the Contractor with all functionality, capabilities and features as described herein. The Contractor shall provide all resources necessary to design, manufacture, deliver, install, demonstrate functional operation, and provide operator and maintenance training for the equipment.

2. Applicable Documents.

2.1 References. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

American National Standards Institute (ANSI)

ANSI AS35411 Fittings and Lubrication

ANSI B93.114M Pneumatic Fluid Power Systems - Standard for

Industrial Equipment and Machine Tool Applications

ANSI 14.2-2017 Ladders, Fixed – Safety Requirements

Institute of Electrical and Electronics Engineers (IEEE)

IEEE C2-2017 2017 National Electrical Safety Code

IEEE STD 142-2007 Recommended Practice for Grounding of Industrial and Commercial Power Systems

International Organization for Standardization (ISO)

ISO 4413:2010 Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components

ISO 4414:2010 Pneumatic Fluid Power - General Rules and Safety

Requirements for Systems and Their Components

National Electrical Manufacturers Association (NEMA)

NEMA 250-2014 Enclosures for Electrical Equipment (1,000 V Maximum)

NEMA MG 1-2016 Motors and Generators

NEMA ICS 1-2000 Industrial Control Systems: General Requirements

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code - 2017 Edition

NFPA 79 Electrical Standard for Industrial Machinery - 2018

Edition

Occupational Safety and Health Administration

29 CFR 1910 Occupational Safety and Health Standards

2.2 Order of Precedence. In the event of a conflict between the text of this Equipment specification and the references cited herein, this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained by the Government.

3.0 Responsibilities.

3.1 Contractor. In addition to the requirements described herein, the Contractor shall be responsible for the following items.

3.1.1 The Contractor shall field verify all test cell dimensions and systems specifications including but not limited to, electrical systems, plumbing systems, pneumatic systems, safety systems, and ventilation systems as compared to ANAD Directorate of Production Engineering (DPE) drawing number PE-12-222 and report any discrepancies to the Government Contracting Officer no later than 30 days after the date of contract award.

3.1.2 The Contractor shall provide all resources to deliver and install the Test Stand in test cell 409 of building 475 at ANAD.

3.1.3 The Contractor shall be responsible for the off-loading of the Test Stand from the shipping transport vehicle immediately upon its arrival at ANAD.

3.1.4 The Contractor shall be responsible for the transport of the Test Stand from the shipping transport vehicle to the installation site.

3.1.5 The Contractor shall be responsible for all movement and final positioning of the Test Stand.

3.1.6 The Contractor shall provide any crane services, fork lift services, lifting beam, and all other equipment required for transport and installation of the Test Stand

3.1.7 The Contractor shall provide all interconnect cables, hoses, manifolds, and regulators and any supporting structure required to connect the Test Stand to the ANAD provided utilities.

The Contractor shall make all connections to ANAD supplied utilities.

3.1.8 The contractor shall provide to the Contract Officer a detailed Gantt type project plan including milestones for the deliverables herein within 21 days after contract award.

3.2 Government. The Government will be responsible for the following items.

3.2.1 ANAD will provide the foundation and utilities shown on ANAD DPE drawing number PE-12-222. Dimensions and locations shown on the drawing are approximate. The Government will not modify as-built dimension and locations to meet the drawing. Upon notification after Contractor field verification of the test cell, the government will provide any utilities shown on the drawing that have been omitted in the as-built test cell.

3.2.2 ANAD will provide access to the installation site during normal operating hours. A request may be made to the ANAD Contracting Officer to allow work outside of normal operating hours. The ANAD Contracting Officer may deny any such request.

3.2.3 ANAD shall provide all transmission parts as required for the tests stated in paragraph 5.3.

3.2.4 ANAD will provide all equipment and labor required for the loading and unloading of transmission parts as required for the tests stated in paragraph 5.3.

4. Test Stand Requirements. The Contractor shall design, manufacture, deliver, install, demonstrate functional operation, and provide operator and maintenance training for the one (1) XT-1410 Transmission Test Stand with all functions, capabilities and equipment as described herein.

4.1 Installation Location. The Test Stand shall be installed at Anniston Army Depot, Anniston, AL in Building 475, test cell W409. A detailed plan of the existing test cell will be provided by the Contract Officer as ANAD Directorate of Production Engineering drawing number PE-12-222. This is not an “As-Built” plan, and as such, the Contractor shall be responsible for verifying all test cell dimensions and systems specifications including but not limited to, electrical systems, plumbing systems, pneumatic systems, safety systems, and ventilation systems.

4.2 Units Under Test. The Test Stand shall be designed to completely mount, connect, and be capable of testing Allison XT-1410-4 and XT-1410-5A transmissions.

4.3 Test Cycle Time. The Test Stand shall be designed and constructed in a way that the time required to prep, load, test, unload, and post-test disassemble the transmission will be no longer than the Cycle Times specified in 4.15.

4.4 Test Stand Utility and Dimensional Requirements. Test Stand shall be installed as shown in ANAD drawing number PE-12-222 referenced in paragraph 3.1. The Test Stand shall be of a “Tee-Shape” and include have an ancillary oil reservoir system and motor variable speed drive cabinet located within the main test cell area. The Test Stand dimensions and location within the test cell shall be such that a minimum of three (3) feet of clearance is allowed between the Test Stand and any test cell structure or utility. The test stand height shall not exceed eight

(8) feet. The following utilities are located within the test cell.

a. Voltage: 480 V 3 phase 60 Hz, 110 V 1 phase 60 Hz

b. Electrical Full Load Amperage (FLA): Not-to-Exceed 1460 amps

c. Electrical KVA: Not-to-Exceed 1200 KVA

d. Compressed Air Pressure Required: Not-to-Exceed 80 psi

e. Compressed Air Consumption: Not-to-Exceed 25 cfm

f. Cooling Water Flow: Not-to-Exceed 30 gpm at 85 degrees from a Cooling Tower

4.5 Test Stand Components and Subsystems. Equipment to be provided under this contract includes the items listed below for one (1) complete and operable Test Stand. Other equipment may be required although not specifically mentioned in these specifications. The following items are listed for the convenience of the Contractor in understanding the scope of supply.

4.5.1 The Test Stand described in this specification shall be capable to perform the test requirements of the NMWR 9-2520-215. The Test Stand shall simulate the vehicle in the test process while providing data readout critical to and indicative of the proper performance of the transmission per the NMWR test requirements.

4.5.2 The Contractor shall design, manufacture, install, calibrate and demonstrate the functional operation of one (1) Test Stand for the XT-1410-4A and XT-1410-5 transmissions.

The Test Stand shall be comprised of seven (7) primary components: Input Drive Unit, Power Absorption Units, Base Frame, Oil Fill Reservoir and Cooling System, Tooling, Instrumentation, and Operator's Control Console with associated software. The Test Stand shall be designed for durability and constructed from materials that will support testing of XT-1410-4A and XT-1410- 5 transmissions at the Production Rates specified in 4.15.

4.5.3 The Test Stand shall be designed and constructed in a way that the time required to prep, load, test, unload, and post-test disassemble the transmission will be no longer than the Cycle Times specified in 4.15.

4.6 Input Drive Unit Assembly.

4.6.1 The Input Drive Unit shall be an off-the-shelf variable speed AC motor matched with a high performance adjustable speed AC drive (ASD) capable of functioning similar to a vehicle engine in terms of load responsiveness and facilitating automatic transmission shifts. The ASD shall be an ABB ACS880 or equivalent with the following salient features: ASD and supporting components mounted in floor mounted enclosure, front mounted operator control panel consisting of minimum of 4-line alphanumeric display which is removable and remote mountable, and compatibility with Drive Composer start-up and maintenance tool. The Input Drive Unit shall be capable of providing the combination of torque and speed (bi-directional) required to meet all test requirements of the transmissions in accordance with the NMWR specified in 4.15.

4.6.2 The Input Drive Unit Assembly shall include the ability to measure the input torque and speeds applied. The Input Drive Unit shall utilize a rotary torque sensor for measurement of input torque and a shaft mounted tachometer for measurement of input speed. The input torque and input speed shall be measured directly by the rotary torque sensor and tachometer and calculated values from the AFD shall not be used. A shaft lock, moment arm and standard weight pan shall be provided for use during calibration of the rotary torque sensor.

4.6.3 The Input Drive Unit Assembly shall at a minimum 400 horse power and have the capability to exceed any NMWR test requirements torque at speed requirements by 25 percent on a continuous duty basis. The Input Drive motor shall have the capability, at a minimum, to exceed any NMWR test speed requirements by 5 percent on a continuous duty basis.

4.6.4 The motor in the Input Drive Unit Assembly shall be coupled inline with the transmission and shall not utilize a torque or speed reduction or multiplication system such as a gearbox.

4.7 Power Absorption Units Assembly.

4.7.1 The Power Absorption Unit Assemblies shall be capable of meeting the test requirements for the transmissions in accordance with the NMWR specified in 4.15. The Power Absorption Units shall be minimal-drag water-cooled eddy-current or air-cooled eddy-current absorbers.

4.7.2 The water-cooled eddy-current absorbers shall require no more than 300 gpm cooling water to cool both absorbers at 85 degrees F cooling water from the Cooling Tower.

4.7.3 Air-cooled eddy-current absorbers require no cooling water, thereby eliminating the need for heat exchangers and their required water source. However, the air-cooled eddy-current absorbers must be capable of meeting the test requirements in accordance with the NMWR specified in 4.15 without excessive heat buildup so that the Test Stand is designed for durability and constructed from materials that will support testing of XT-1410-4A and XT-1410-5 transmissions at the Production Rates and Cycle Times specified in 4.15.

4.7.4 The Power Absorption Units shall be bi-directional with full load capability in either direction of rotation. Infinitely variable control from no-load to full-load shall be accomplished via the Operator's Console specified below.

4.7.5 The Power Absorption Unit Assemblies shall include the ability to measure the output torque, both running and stalled, and output speed of the transmission including when the outputs are stalled.

4.7.6 The Power Absorption Unit Assemblies shall be equipped with an automatic stall brake device capable of meeting the test requirements for the transmissions in accordance with the NMWR.

4.7.7 The Power Absorption Unit Assemblies shall have the capability, at a minimum, to exceed any NMWR test requirements by 25 percent of full load stall torque and 20 percent of full speed in either direction of rotation.

4.7.8 The Power Absorption Unit Assemblies shall be equipped, if required, with a flywheel to simulate vehicle inertia.

4.8 Test Stand Base Frame.

4.8.1 The Input Drive Unit Assembly (specified above), and Power Absorption Unit Assemblies (specified above), shall be constructed on a common Test Stand Base Frame and include a “cradle” transmission support structure. The Test Stand Base Frame shall have the provisions to support the transmission assembly at the output trunnions and the input mount flange. The Test Stand Base Frame shall be constructed with a welded steel frame for high structural integrity and rigidity.

4.8.2 The Test Stand Base Frame shall incorporate an integral oil spill reservoir with a sump pump to return any captured oil, through filters and hose, back to the main Oil Fill Reservoir specified below. The oil spill reservoir shall be covered with a screened grate-type cover capable of supporting 300 pounds while allowing drainage to the reservoir.

4.9 Oil Fill Reservoir and Cooling System.

4.9.1 The Test Stand shall have an Oil Fill Reservoir and Cooling System. The system shall be designed to fill the transmission with the required amount of oil and, after testing, pump the oil out of the transmission.

4.9.2 The main Oil Fill Reservoir shall provide the oil supply to the transmission and shall include a reversible pump, filters, and heaters to preheat the oil. The pump shall be reversible in order to fill and drain oil to and from the transmission. The main Oil Fill Reservoir shall be, at a minimum, a 120-gallon JIC reservoir and include an oil level sight gauge, temperature gauge, riser with filler breather rated at 40 microns, and a 3/4-inch NPT drain in the bottom of the Reservoir. The main Oil Reservoir shall have reasonable access for cleaning within the Test

Cell. The pump control shall be in close proximity to the transmission dipsticks for operator convenience.

4.9.3 The Cooling System shall be designed to maintain the temperature of the transmission oil in accordance with the NMWR test requirements. The Cooling System shall be designed to circulate the oil to an oil-to-water heat exchanger & filtration system to provide closed-loop temperature control of the oil during testing. Automatic temperature control valves shall regulate the water flow to the heat exchanger.

4.10 Test Stand Tooling - Adapters, Actuators, Cables, and Other Hardware.

4.10.1 Test Stand Tooling shall include all adapters, actuators, control cables and other hardware required to completely mount, connect and test the XT-1410-4A and XT-1410-5 transmissions.

4.10.2 Provisions shall be made for coupling the Input Drive Unit Assembly shaft, specified above, to the transmission input shaft. Provisions shall be made to adapt the transmission output flanges and shafts to the test stand cradle supports and Power Absorption Unit Assembly shafts.

Such provisions shall provide means to retain the brake oil coolant and measure brake oil coolant pressure on both the left and right transmission outputs. Couplings shall be “slide” type and utilize a rack and pinion system to couple and uncouple the transmission output shafts from the Power Absorption Unit Assembly shafts. Input and output shaft guards shall be provided and shall consist of two (2) hinged half-tubes connected to each other and locked by a quick fastener suitable for containing the drive shaft and coupling package in the event of a failure. A safety switch shall check whether the shaft guard is open or closed and shall prevent the starting of the test run in case of an open shaft guard.

4.10.3 Provisions shall be made for actuators and/or control cables as required for automatic control of items such as steer, brake, and shift controls for the transmission.

4.10.4 The test stand shall be so designed that the transmission may be installed using quick-connect fittings and drive shaft connections with minimum adjustments for the transmission being tested.

4.11 Test Stand Instrumentation.

4.11.1 The Test Stand Instrumentation shall incorporate the necessary transducers, signal conditioning, and data acquisition required to measure, display and record all parameters required by the NMWR including but not limited to the following parameters during transmission testing:

PARAMETERS RANGE *ACCURACY

Input speed 0-2500 RPM +/- 1% Input torque 0-2000 lb-ft +/- 1% Output speed 0-2500 RPM +/- 1%

Output torque, running and stalled 0-5000 lb-ft +/- 1% Converter-Out oil temperature 0-300 F +/- 1% Converter-Out oil pressure 0-200 PSI +/- 1% Converter-In oil pressure 0-200 PSI +/- 1% Steer Supply oil pressure 0-200 PSI +/- 1% Right Steer Clutch Apply oil pressure 0-200 PSI +/- 1% Left Steer Clutch Apply oil pressure 0-200 PSI +/- 1% Main oil pressure 0-400 PSI +/- 1% Low Range Clutch Apply oil pressure 0-400 PSI +/- 1% Intermediate Range Clutch Apply oil pressure 0-200 PSI +/- 1% Reverse Range Clutch Apply oil pressure 0-400 PSI +/- 1% High Range Clutch Apply oil pressure 0-200 PSI +/- 1% Lubricating oil pressure 0-60 PSI +/- 1% Lockup Clutch Apply oil pressure 0-300 PSI +/- 1% Governor pressure 0-60 PSI +/- 1% Cooler oil flow 0-50 GPM +/- 1% Left Brake Coolant oil pressure 0-60 PSI +/- 1% Left Brake Coolant oil pressure 0-60 PSI +/- 1%

*Accuracy is based on full-scale reading

4.11.2 Pressure transducer circuits shall incorporate snubbers, ball valves and fittings to facilitate calibration of the transducers with a hydraulic hand pump.

4.11.3 When a programmable logic controller (PLC) is used as part of the test stand, that PLC shall have the following salient features: compatibility with Allen Bradley RSLogix programming and maintenance software and compatibility with Allen Bradley communication cables.

4.12 Operator's Controls.

4.12.1 The Operator Controls and associated equipment shall be located in the Test Cell Control Room. The Operator Controls shall include all controls, instrumentation, and indicators required to test the transmissions in accordance with the NMWR test requirements specified in 4.15.

4.12.2 The Operator Controls shall include a computer, keyboard, monitor(s), printer, emergency stop control, and all controls required to operate the Test Stand and control the transmission under test. If a desktop surface is required, the Contractor shall provide a laminate countertop surface 24 inches deep and sufficient to hold all items listed above with an additional 3 linear feet or more of free space to be used as an operator work desk.

4.12.3 All Test Stand Instrumentation shall be monitored by the control system and displayed on a computer monitor as virtual instruments (gages, sliders, meters, lights, etc.).

4.12.4 The Test Stand shall normally be computer controlled in the semi-automatic mode.

The Operator Controls shall provide the capability for the operator to manually perform transmission tests via the computer. The manual mode of operation shall provide all control functions to allow the operator to completely control all aspects of the transmission test operations. In manual mode the operator shall be responsible for all Test Stand startup sequencing, emergency shutdowns, test sequence operations, and data collection.

4.12.5 Communication between the data acquisition system and the computer shall be an open industry standard, including, but not limited to IEEE 1394, RS-232, RS-485, Ethernet, Universal Serial Bus (USB), or equivalent

4.12.6 All computer hardware shall be open architecture, consisting of standard hardware that can be replaced by commercially available parts. The computer shall meet the following minimum requirements:

a. A workstation class computer operating on Windows 10 Professional 64-bit built by a major computer OEM such as Hewlett Packard or Dell.

b. Intel Xeon microprocessor operating at a minimum of 3.6 GHz base frequency

c. Minimum of 16 GB (gigabytes) of Random Access Memory (RAM)

d. Two (2) identical 7200 rpm enterprise grade SATA internal HDD with a minimum capacity of 1 TB each installed in a RAID 1 mirrored array configuration for real-time backup

e. Internal DVD writer optical disc drive

f. Ergonomic English Language QWERTY type USB wired extended keyboard, with a minimum of ten (10) function keys, cursor keys, and numeric keypad -keyboard design shall be compatible with the environmental conditions surrounding the operator's console

g. One (1) wired USB optical wheel mouse

h. One (1) color printer capable of printing a minimum of 30 pages per minute

i. One (1) or two (2) 24-inch (minimum) TFT active matrix LCD color monitor(s) capable of a maximum resolution of 1920 X 1200 pixels and display at least 16.7 million colors (24 bit) - monitor shall be installed in a convenient location to allow the operator to view the monitor, operate the Operator Controls, and view the transmission through the Control Room window.

j. One (1) 1000VA or greater Un-Interruptible Power Supply (UPS)

4.12.7 Software shall be provided to perform the following functions:

a. Operating System - The data acquisition and control software shall be the latest released (stable) version of a commercial application package commonly used for real-time control and data acquisition, instrument control, and industrial automation.

The applications software shall contain all utilities, instrument drivers, and libraries required to maintain or modify the Contractor developed test sequences supplied with the system. A copy of any compilers, assemblers, linkers, program editors, or other software tools used to create the contractor-developed test sequences shall be delivered on CD/DVD with the Test Stand. The Contractor shall deliver the original install CD/DVD (or CD/DVDs) containing the executable machine code and/or runtime engine for the application package with the Test Stand. This will permit automatic single-installer installation, uninstallation or repair of the application software in the event of hard disk failure.

b. Test Sequence Software - The Contractor shall develop a series of pre-programmed test sequences that meet all test requirements for the transmissions in accordance with the NMWR specified in 4.15. In the semi-automatic mode, the software shall perform Test Stand startup sequencing, emergency shutdowns, monitoring of limits, receiving operator input and translating them into control actions. The software shall require operator interaction to select the appropriate individual test to be executed from a menu. The software shall also allow the operator to stop and then restart a test step without having to restart the entire test sequence. The software shall automatically perform data acquisition required by the selected test. After execution of the selected individual test has been completed, semi-automatic test sequencing shall be halted awaiting further action by the operator.

The software shall generate a report of the test results including pass/fail limits and pass/fail status for each measurement at the completion of the test when requested by the operator. If a transmission fails a particular test, the test sequence shall indicate to the operator the failed test results. The software shall also include the capability for user defined and savable test sequences.

c. Display Software - The software shall display messages describing adjustments or other actions to be taken by the operator during transmission testing. All designated safety alarm conditions shall be displayed in red and all test limit alarms shall be displayed in yellow.

d. Data Management and Report Generation Software - The Contractor shall provide data management utilities with the following minimum capabilities:

Accepts operator input for the new transmission or recall data from previously tested transmissions to allow certain tests to be rerun.

Stores data after each test step is completed.

Prints a test report showing test data, highlighting failed data by showing pass/fail limits and pass/fail status if applicable.

Allow on-screen viewing/editing of final test data before printing.

Search history files by serial numbers, display reports, and print on demand.

4.12.8 The Test Cell data acquisition and control software shall also be capable of the following:

a. Report generation shall be in accordance with NMWR 9-2520-215.

b. Calibration: The calibration routine shall include a wizard driven menu to assist in the calibration process. Calibration records shall be kept in a file on the system and shall be accessible for review.

4.12.9 The Test Stand shall be fitted with an hour meter to measure operating time. The time totaling meter shall be the non-resetting type and shall have a range of 0 to 100,000 hours in increments of 1 hour and 99999 shall be the maximum readout. The least significant digit on the meter readout shall be 1 hour. Upon reaching the maximum accumulative hours, the meter readout shall automatically revert to zero and continue to total time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the Test Stand. The meter shall be located as to be readily visible, but not subject to abuse relative to the operating environment of the Test Stand. The hour meter shall be connected such that it measures the time that the field of the motor in the Input Drive Unit Assembly is energized.

4.13 Spare Parts Kit.

A spare parts kit shall be included with delivery of the Test Stand. The kit shall include one (1) set of Contractor recommended spare parts.

4.14 Hardware and Special Tools.

All hardware and special tools required for the complete and proper installation, operation, and maintenance of the Test Stand shall be furnished.

4.15 Performance Requirements. The Test Stand shall be capable of testing the transmissions specified below at the process requirements of referenced NMWR specified below.

4.15.1 Accuracy

4.15.1.1 The Test Stand shall be capable of controlling the load on the transmission as specified in the test requirements of the NMWR specified below.

4.15.1.2 The Test Stand Instrumentation specified above and any other instrumentation required for the Test Stand shall be verified for calibration accuracy by comparison with standard measuring devices having an overall accuracy error within 1/4 of one percent of the value being measured. Each instrument shall be inspected to determine conformance to appropriate requirements for accuracy.

4.15.2 Transmissions to be Processed

4.15.2.1 The XT-1410 Transmission Test Stand shall be capable of testing of the following transmissions:

a. Allison XT-1410-4

b. Allison XT-1410-5A

4.15.3 Production Rates, Speeds, Cycle Times

4.15.3.1 Production Rates - The XT-1410 Transmission Test Stand shall be capable of testing the transmissions specified above at an average Production Rate of greater than two (greater than

2) transmissions per eight (8) hour shift (385 min. available work time per 8-hour shift).

4.15.3.2 Cycle Time - The Test Stand shall be designed and constructed in a way that the time required to prep, load, test, unload, and post disassemble the transmission shall not exceed an average Cycle Time of one hundred fifty (150) minutes. This average Cycle Time would not include any minor repairs and adjustments that may be required on a rebuilt transmission.

4.15.4 Equipment Capable of Test Requirements for Referenced NMWR

4.15.4.1 XT-1410 Transmission Final Assembly Test Requirements are referenced as follows:

a. NMWR 9-2520-215, XT-1410-4 and XT-1410-5A Cross-Drive Transmission Assembly, WP 0020-00, Final Assembly and Testing.

4.15.5 Quantity and Qualifications of Production Personnel Required to Operate Equipment

There is one (1) XT-1410 Transmission Test Cell presently in production in Building 129 at ANAD that test the transmissions specified above. The qualifications required of the present production personnel shall be those that are required to operate this new XT-1410 Transmission Test Stand specified. One (1) operator shall be assigned to operate this new XT-1410 Transmission Test Stand in Building 475.

4.16 Additional Requirements.

4.16.1 Original Equipment Manufacturer Years of Operation

4.16.1.1 Original Equipment Manufacturer shall have at least 15 years of operation.

4.16.2 Original Equipment Manufacturer Years of Manufacturing Cross-Drive Transmission Test Stands

4.16.2.1 Original Equipment Manufacturer shall have at least 10 years experience in building and servicing cross-drive transmission test stands.

4.16.3 Quantity of Cross-Drive Transmission Test Stands Presently in Production by Original Equipment Manufacturer

4.16.3.1 Original Equipment Manufacturer shall have at least 10 units similar to the proposed cross-drive transmission test stand in operation in a similar type of process.

4.16.4 Customer References for Cross-Drive Transmission Test Stands

4.16.4.1 Original Equipment Manufacturer shall provide at least 5 references similar to the proposed cross-drive transmission test stands.

4.16.5 Original Equipment Manufacturer Repair Service Capability

4.16.5.1 Original Equipment Manufacturer shall have an adequate staff to provide cross-drive transmission test stand maintenance response within 48 hours or less.

4.17 General Requirements.

4.17.1 General.

4. 17.1.1 Original Equipment Manufacturer's part numbers referenced herein are intended to be descriptive and not restrictive; and are not intended to preclude the use of any item otherwise conforming to this specification.

4. 17.1.2 The Test Stand and its components shall be standard unmodified products of an Original Equipment Manufacturer regularly engaged in the manufacturing of such products.

Components of the same type and purpose shall be identical and supplied by the same manufacturer.

4. 17.1.3 The Test Stand (as defined in this specification) includes the engineering, selection, procurement, design, manufacture, assembly, testing, delivery, installation, training and commission, and includes all related equipment, spare parts, materials, supplies, components, documentation, and all other items required to make a production ready system.

4. 17.1.4 The Contractor shall not install ventilation or exhaust systems in a manner or location that interferes with the Test Stand or existing equipment, or interferes with personnel access to the Test Stand or existing equipment for operation or maintenance. The Contractor shall not install ventilation or exhaust systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install ventilation or exhaust systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.17.2 Electrical Requirements.

4.17.2.1 All electrical work shall comply with IEEE C2, NFPA 70, and, unless outdoors or in an electrically hazardous classified area, shall be installed to meet NEMA 13 rating. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings. Workmanship shall be in accordance with standard commercial practices. All wire shall be copper; no aluminum wire shall be used. Conduit feeds to the T shall be IMC or rigid conduit. Conduit runs shall be installed perpendicular and parallel to facilities and the Test Stand to be installed. When the Test Stand is installed near existing power lines, the Test Stand shall be located for proper clearances in accordance with IEEE C2. Oil-resistant, liquid-tight, flexible metal conduit may be used to connect to Test Stand components (valves, motors, switches, sensors) but the length shall not exceed six (6) feet.

4.17.2.2 The Contractor shall not install conduit in a manner or location that interferes with equipment, or interferes with personnel access to the Test Stand or existing equipment for operation or maintenance. The Contractor shall not install conduit in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking.

The Contractor shall not install conduit in a manner or location that interferes or in any way limits the full design motion of any crane.

4.17.2.2.1 Test Stand Service Voltage - The Test Stand shall be wired to draw all of its electrical power from a single circuit. If the Test Stands’s single circuit amperage does not exceed the requirement of a 20-amp circuit, the Test Stand may be designed to operate on 120-volt, 1-phase, 60-Hertz (Hz) input power. If the Test Stand’s single circuit amperage exceeds the requirement of a 20-amp circuit, the Test Stand shall be designed to operate on 480-volt, 60-Hertz (Hz) input power. The Test Stand shall be equipped with a manual, fused, or breaker type disconnect switch, readily accessible to the operator, that will deactivate the entire Test Stand.

4.17.2.2.2 Electrical Noise - The electrical power at ANAD may be subject to electrical noise.

If the Test Stand requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the Test Stand. If the Test Stand is subject to interference from adjacent machinery, the Test Stand shall include the proper shielding to prevent malfunctions.

4.17.2.2.3 Electrical Connections - Connections to screw-type terminals shall be mechanically secured with means to prevent loss of tightness. All other electrical connections shall be mechanically secured and soldered or brazed. Rosin base fluxes shall be used in all soldering operations.

4.17.2.3 The Test Stand process parameters and machine functions shall be automatically, continuously monitored and maintenance warnings automatically issued before any parameter reaches unacceptable levels.

4.17.2.4 The Test Stand shall be equipped with suitable grounding devices for static discharge.

4.17.3 Motors.

4.17.3.1 Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors, unless otherwise specified, shall conform to the requirements of NEMA MG 1. Motors shall be AC, 60-Hz, or DC industrial-type motors with drip proof enclosures. All motors 10 HP or greater shall have a soft start controller. Each motor control shall conform to the requirements of NEMA ICS 1.

4.17.4 Pneumatic Systems.

4.17.4.1 If the Test Stand requires a pneumatic system, the pneumatic system shall conform to the requirements of ANSI B93.114M and Section 43 15 00.00 20 E, LOW PRESSURE COMPRESSED AIR PIPING (NON-BREATHING AIR TYPE) applies to this section. The pneumatic system shall comply with ISO 4414:1998 and NFPA T2.25.1R2 200x.

4.17.4.2 The Contractor shall not install pneumatic systems in a manner or location that interferes with the Test Stand or existing equipment, or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install pneumatic systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install pneumatic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.17.5 Hydraulic Systems.

4.17.5.1 If the Test Stand requires a hydraulic system, the hydraulic system shall conform to the requirements of NFPA / JIC T2.24.1R1. The hydraulic system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in the high-pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, a provision for draining, and a cleanout access plate if the reservoir is not removable.

4.17.5.2 The system shall be equipped with a hydraulic fluid requirements plate attached to the Test Stand at the hydraulic reservoir fill point. The plate shall contain the Type of fluid (SAE or Military or Federal specification number) and Type of filter.

4.17.5.3 The Contractor shall not install hydraulic systems in a manner or location that interferes with the Test Stand or existing equipment, or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install hydraulic systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install hydraulic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.17.6 Plumbing, Drainage and Waste.

4.17.6.1 If the Test Stand requires chilled water, incoming water lines shall have adequate anti-siphon provisions to prevent water supply contamination.

4.17.6.2 If the Test Stand requires water, the contractor shall install a Fresh Water Back Flow Check Valve.

4.17.6.3 The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the Test Stand or existing equipment, or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.17.7 Foundation.

4.17.7.1 The Test Stand shall utilize the existing foundation in Cell W409 located in Building

475. Foundation dimensions and specifications are shown in ANAD drawing number PE-12- 222, Sheet 2. The Contractor shall be responsible for field verifying all foundation dimensions and specifications as required. The Contractor shall perform any required modifications to the existing foundation. The Test Stand shall have tie-down anchoring bolts and leveling bolts on the base to facilitate leveling and shall meet all manufacture's requirements.

4.17.8 Safety and Health Requirements.

4.17.8.1 The Test Stand shall comply with OSHA limitations and control of noise levels, radiation, electromagnetic emission, noxious vapors, heats etc, as applicable.

4.17.8.2 The Test Stand shall be equipped with safety devices to adequately protect the operator from all hazards incident to its operation.

4.17.8.3 The Test Stand shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910. The Test Stand shall include warning lights/indicators to alert the Test Stand operator to unsafe operating conditions. The Test Stand shall include a manual emergency shutdown switch and shall have the ability to automatically shut down when under automatic control. All parts, components, mechanisms, and assemblies furnished on the Test Stand, whether or not specifically required herein, shall conform to all requirements of OSHA 29 CFR 1910. Covers, guards, or other safety devices normally furnished as standard on the manufacturer's commercial Test Stands supplied to the commercial market shall be provided for the point of operation and all other parts of the Test Stand that present safety hazards. All special guarding shall meet OSHA 29 CFR 1910. The safety devices shall not interfere with the operation of the Test Stand. All guards shall allow access to the guarded part(s).

4.17.8.4 Safety devices shall be provided for all parts of the Test Stand presenting safety hazards. Guards shall be removable to provide easy access to the guarded parts. The Test Stand shall comply with the standards promulgated under OSHA 29 CFR 1910 that are applicable to the Test Stand itself.

4.17.8.5 Protection against electric shock shall be incorporated. All front access panels and doors shall be furnished with electrical interlocks to remove power from the cabinets while panels or doors are open.

4.17.8.6 Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment, visible to maintenance personnel and permanently marked.

4.17.8.7 Noise Level. Noise emitted by the Test Stand shall be no greater than 80 decibels.

The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the Test Stand into conformance with this requirement shall not interfere with visibility needed for safe operation of the Test Stand. Operators shall be able to use this Test Stand without the need for hearing protection.

4.17.8.8 Ergonomics. The Test Stand shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

4.17.9 Environmental Compliance. The Test Stand provided under this contract shall meet all applicable Environmental Protection Agency (EPA) and Alabama Department of Environmental Management (ADEM) regulations and restrictions in effect on the date of the contract.

4.17.10 Energy Efficiency. The Test Stand and its components that directly consume energy in normal operation shall be designed and constructed for energy efficiency in accordance with the developments available within the industry. Pneumatic circuits shall be designed for minimum air consumption.

4.17.11 Documentation. The contractor shall provide all documentation with the Test Stand as specified herein.

4.17.12 System of Units. The Test Stand shall display all units of measure in the U.S.

Customary System of Units "English", not Metric.

4.17.13 Nameplates.

4.17.13.1 The Equipment shall have the manufacturer's name and address, and the model and serial number in a conspicuous place.

4.17.13.2 A nameplate shall be mechanically attached to the Test Stand – adhesive alone will not be considered sufficient to meet this requirement, and shall contain, at a minimum, the following information:

a. Nomenclature.

b. Manufacturer's name, Address and Phone Number.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Facility Circuit Breaker or Buss Duct Switch Location Reference Number

g. Short-circuit/over current rating.

h. Contract number.

i. National stock number (if applicable).

j. Date of manufacture.

4.17.13.3 Laminated plastic nameplates shall be provided for equipment devices and panels furnished. Each nameplate shall identify the device; such as pump "P-1" or valve "VLV-402".

Laminated plastic shall be 1/8 inch thick, white with black center core. Nameplates shall be a minimum of 1 by 3 inches with minimum 1/4 inch high-engraved block lettering. Nameplates for devices smaller than 1 by 3 inches shall be attached by a stainless steel chain or cable. All other nameplates shall be mechanically attached to the Test Stand or panel surface next to the device – adhesive alone will not be considered sufficient to meet this requirement. The nameplate shall remain in place, undisturbed, when a component is replaced.

4.17.13.4 All words on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background. All plates shall be corrosion resistant. All plates shall be mechanically attached to the Test Stand – adhesive alone will not be considered sufficient to meet this requirement.

4.17.14 Maintainability and Interchangeability. The Test Stand shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. When non-commercial off-the-shelf components are used the Contractor shall provide all documentation including any electronic files and a manufacturing source required for production of those components. All replaceable parts shall be designed and manufactured to such standards as shall permit replacement and adjustment without the need for modification of the parts or the Equipment. All replacement parts shall be available domestically.

4.17.15 Workmanship. Standards of workmanship shall assure that the test stand shall have the stability, strength, safety, and efficient operating characteristics found in state of the market commercial units.

4.17.16 Tools. All tools, other than common hand tools, required for normal operation and maintenance of the Test Stand shall be provided.

4.17.17 Construction.

4.17.17.1 The Test Stand shall be so constructed as to be capable of performing the operations specified herein. All surfaces shall be clean and free of extraneous materials. External surfaces shall be smooth and free from sharp edges, rounded or beveled, unless sharpness is required for performance. All screws, pins, and similar parts shall be installed to prevent loss of tightness.

Parts subject to adjustment or removal shall not be permanently installed or deformed. The Test Stand shall be constructed of parts, which are new, without defects, and free of repairs. The structures shall withstand all forces encountered during operation of the Test Stand to its maximum rating and capacity without permanent distortion or failure.

4.17.17.2 Materials shall conform to the applicable specifications and shall be as specified herein and on the applicable drawings.