1. Missle Maintenance Van Purchase Description.pdf

Purchase Description Truck, Diesel, Crew Cab, 4X2, Van Body, Modified

NSN 2320-01-375-5833

Note to Offerers: Offerers shall explicitly and completely identify any and all exceptions taken to the requirements of this specification. Drawings, literature, and any other information submitted with an offer do not constitute a stated or implied exception unless specifically identified in writing as an exception and accepted and implemented by an amendment to the solicitation or modification to a contract. Any exception deemed acceptable by the Government shall only apply to the specific item, requirement, etc. cited, and shall not extend to any other requirement

Offerers offering other than brand name items identified below, when an “or equal” may be acceptable, shall furnish with their offers all technical data information, product descriptions, etc. to ensure that a determination may be made as to the equality of the product(s) offered (see clause titled “Brand Name or Equal” set forth in Section 552.210-74 of the GSA Acquisition Regulations.)

1. SCOPE

This description is for a modified van truck to be utilized by the Air Force.

2. APPLICABLE DOCUMENTS

2.1 SOCIETY OF AUTOMOTIVE ENGINEERS, INC.

SAE J1292 Automobile, Truck, Truck-Tractor, Trailer Wiring- Recommended Practice

SAE J429 Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J1199 Mechanical and Material Requirements for Metric Externally Threaded Steel Fasteners

SAE J163 Low Tension Wiring and Cable Terminals and Splice Clips

SAE J561 Electric Terminals-Eylet and Spade Type

SAE J858a Electric Terminals-Blade Type

SAE J928 Electric terminals-Pin and Receptacle Type

Applications for copies of SAE publications should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale, PA 15096

2.2 MILITARY STANDARDS AND HANDBOOKS

MIL-HDBK-1223 -Handbook—Nontactical Wheeled Vehicles Identification Marking and Data Plate Standards

Unless otherwise indicated, copies of Federal and military specifications, standards, and handbooks are available from Naval Publications and Forms

Center, Military Specifications and Standards, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094. Military specifications and standards are also available for downloading on the Internet through the Department of Defense Single Stock Point for Military Specifications, Standards, and Related Publications (DODSSP). DODSSP is the gateway link site to the Acquisition Streamlining and Standardization System (ASSIST and ASSIST-On Line) and may be accessed at http://dodssp.daps.mil.

2.3 OTHER STANDARDS

ASME/ANSI B18.18.1M Inspection and Quality Assurance for General Purpose Fasteners

ANSI publications may be accessed at:

http://webstore.ansi.org/ansidocstore/default.asp

TMC RP 403- Placement of Safety Equipment and TMC RP 711-12 Year Life Swing Type Dry Freight Van Trailer Doors

Published by The Technical and Maintenance Council of the American Trucking Association, 2200 Mill Road, Alexandria, VA 22314

2.4 ORDER OF PRECEDENCE

In the event of a conflict between the text of this purchase description and the references cited above, this purchase description takes precedence. Nothing in this purchase description, however, supercedes applicable state and federal safety laws and regulations and the requirements set forth in the vehicle manufacturer’s Bodybuilders and Incomplete Vehicle Manuals.

3. REQUIREMENTS

Materials shall be as specified herein. When materials are not specified, the vehicle and all parts thereof shall be furnished to provide the intended function, durability, safety, and maintain good long term appearance. All materials shall be new, shall be suitable for the intended purpose, and shall be free of any characteristics or defects in material and workmanship, which may affect the performance, function, durability, and serviceability of the finished vehicle, or detract from its appearance. The government reserves the right to make the final determination of the suitability of all components and their arrangement on and in the vehicle.

All modifications and additions to the chassis shall conform to all requirements of the chassis manufacturer’s Body Builders Layout Book and Incomplete Vehicle Manual applicable to the incomplete chassis model and year of manufacture. The truck shall be capable of being operated in the continental United States and fully functional in the following operating conditions:

Temperature range: -40 to +115 deg F

Improved and unimproved roads

Mountainous terrain

Snow, mud, and ice conditions http://dodssp.daps.mil/

The truck chassis and completed vehicle shall conform to the requirements of CFR 49 Part 571- Federal Motor Vehicle Safety Standards (FMVSS), and the completed vehicle shall conform to CFR 49 Part 393 of the Federal Motor Carrier Safety Regulations

(FMCSR).

3.1 TRUCK VAN WITH CREW CAB

3.1.1 TRUCK CHASSIS

Chassis exhaust emissions requirements:

Exhaust emissions for all heavy duty diesel engines and vehicles over 8500 pounds GVWR equipped with heavy duty diesel engines shall comply with the requirements in the Code of Federal Regulations Title 40 Subchapter C- Part 86, “Control of Emissions from New and In-use High-way Vehicles and Engines” section 86.007-11 “Emission standards and supplemental requirements for 2007 and later model year diesel heavy-duty engines and vehicles” in addition to the following requirements:

Exhaust emissions for particulates shall not exceed 0.01 grams per brake horsepower-hour (g/bhp-hr). The use of the Average, Banking, Trading (ABT) Program as referenced in CFR Title 40 Subchapter C-Part 86 section 86.007-15 shall not apply to the exhaust emissions attainment levels for particulates.

Exclusions, exemptions and nonconformance penalties, that may be available under other provisions in the Environmental Protection Agency’s programs, shall not apply to the exhaust emissions requirements for particulates referenced above.

The chassis shall be a current year model crew cab, 4X2, conventional truck chassis furnished with all the offeror’s standard equipment and meeting the following minimum requirements and furnished with the following optional equipment:

GVWR 31,000 lbs.

Minimum Payload 7500 lbs. (GVWR minus curb weight of completed vehicle) CA As required for 20 ft. body Front axle 10,000 lbs. rating Rear axle 21,000 lbs rating, sgl. speed, with automatic traction control Axle seals oil Wheel ends hub piloted Suspension minimum 9000 lbs front, 19,000 lbs rear Engine minimum 275 hp 800 ft-lbs torque Transmission automatic-5 speed Max Governed Speed 70-75 MPH Coolant protection to -63 deg F.

Frame RBM minimum 900,000 in-lbs RBM Brakes full air

Steering power Wheels disc Tires 10R22.5G/Highway Front; 10R22.5G/ All Terrain Rear with minimum speed rating of 75 MPH Alternator minimum 145 amp Battery min 535 CCA/540 minute reserve Exhaust type Vertical exhaust pipe and muffler Fuel Tank Dual tanks, minimum 50 gallon working capacity each tank Mirrors heated, motorized RH mirror Horn electric and air Seats air ride drivers seat, fixed passenger seat Back Up Alarm required Wipers intermittent Radio AM/FM/CD player Engine Hour Meter required Chassis Color Cab exterior color shall be OEM color closest to Air Force

Strata Blue, Federal Standard color 15042.

3.1.1.2 Air Conditioning

The chassis OEM’s standard chassis air conditioning shall be furnished.

3.1.2 FUEL FIRED ENGINE PRE-HEATER

A diesel fuel fired engine water heater shall be provided to preheat the engine. The heater shall include a timer, a thermostat and a circulating pump, and shall be connected to the engine coolant system. The heater shall be capable of starting and operating at -40°F and shall heat the engine to 40°F from -40°F in not more than 1 hour.

The system shall be equipped with a start light, visible to the seated driver, to indicate that the pre-heater is operating. The pre-heater shall be a Webasto model Thermo 90 ST, or equal.

Offering: Diesel fired coolant pre-heater

Manufacturer: ____________________________________________________

Model: ____________________________________________________________

3.1.3 FUEL FIRED CAB HEATER

A diesel fired auxiliary air heater shall be furnished in the cab. The heater shall be located under the rear passenger seat in a location that prevents possible damage by passenger’s feet. The heater shall blow air toward the front of the cab. The heater shall have a minimum rated capacity of 12,500 BTU/hr and be capable of delivering 125 CFM air flow. A drain pan equipped with a drain hose shall be mounted under the heater cores and vented through the floor to the outside. A rubber grommet shall be installed in the floor hole to prevent hose damage and to keep cold air from entering. The cab air heater shall be a Webasto Air Top 5000 or equal.

Offering: Cab auxiliary air heater

Manufacturer: _________________________________________________________

Model: _______________________________________________________________

3.1.4 IN-LINE FUEL HEATER

An in-line fuel heater, utilizing engine coolant, shall be furnished to prevent fuel filter clogging due to waxing of the fuel. The unit shall transfer sufficient heat to the fuel to raise the fuel temperature from -40 deg F to plus 9 deg F with a fuel flow rate not less than the maximum fuel demand of the engine. A coolant shutoff valve shall be furnished on the coolant entry side of the warmer.

3.1.5 OIL PAN HEATER

An electric surface type heater - not more than 2.8 watts per square centimeter (W/cm2) (18 watts per square inch) or less than 1.4 watt/sq. cm (9 watts per sq. in.) heating capacity shall be furnished. If the design of the bottom of the oil pan dose not allow for a surface type heater, an immersion type heater shall be furnished. If an immersion type heater is offered, it shall be approved by the Government.

The oil pan heater shall conform to all requirements of Federal Motor Carrier Safety Regulation 393.77(b) (7).

Offering: Oil Pan Heater

Manufacturer: _________________________________________________________

Model: _______________________________________________________________

3.1.6 CREW CAB

The cab interior shall be furnished with two dome lights, one for the front seat and one for the rear seat. Each shall be equipped with dual, adjustable, high intensity map lights.

The dome lighting shall illuminate the entire cab area. The crew cab shall be furnished with a full headliner. Full insulation shall be furnished in the cab and firewall. Rear door windows and rear window shall be furnished with darkest available aftermarket tint. The remainder of the windows shall be furnished with the darkest legal tint commercially available.

3.1.7 MILITARY MARKING

Markings and data plates shall conform to MIL-HDBK 1223 with the following exception:

"US AIR FORCE", "VEHICLE REG. NUMBER" AND "FOR OFFICIAL USE ONLY" are not required on the sides or rear of the vehicle; however, the contract number is required on the data plate in conformance with MIL-HDBK 1223, and on DD Form 250.

A Vehicle Data Plate shall be furnished on each and every vehicle delivered, in accordance with MIL-STD-1223 and with the addition of two new fields, “Ship To” and

“Mark For”. The Data Plate shall be permanently attached to the vehicle under the hood, if possible. If not, the data plate shall be placed inside the door or in the glove box. The following information, at a minimum, shall be included on the Data Plate:

NOMENCLATURE TRUCK-DIESEL-CREW CAB-4X2-VAN-MODIFIED

MAKE AND MODEL_______________________________________

MANUFACTURES SERIAL NUMBER (VIN) _____________________

REGISTRATION NUMBER _________________________________*

NSN NUMBER __________________________________________*

VEHICLE CURB WEIGHT ________________________________ LBS

PAYLOAD, MAXIMUM____________________________________LBS

GROSS WEIGHT, MAX __________________________________ LBS

GROSS WEIGHT COMB________ _________________________ LBS

DATE OF DELIVERY _____________________________________

WARRANTY___________________MOS___________________MILES

CONTRACT NUMBER___________________________________

SHIP TO _______________________________________________

MARK FOR _____________________________________________

US PROPERTY

* Number (s) provided to the successful offeror after contract award

3.1.8 HYDRAULIC TAILGATE, FOLD UNDER

A hydraulic fold under tailgate shall be furnished. The tailgate shall be a non-level load type so that the leading edge of the ramp meets the ground. It shall have a wide arm design for platform stability when corner loaded and have a rated capacity of 2500 pounds. The platform shall be 38 inches by 72 inches, plus a 4 inch ramp (plus or minus

1.5 inch). The tailgate shall be operable at temperatures as low as -40 degrees F. The top surface of the platform and extension shall be coated with non-skid paint. Two fold-down steps shall be mounted to the vertical support of the tailgate assembly that is located directly below the rear doorframe. The bottom step shall be located as low as practicable and the upper step shall be located 12 inches (nominal) above the bottom step. An 18 inch (nominal) long, nylon pull strap shall be mounted 18 +/- ½ inches from the floor on the rearmost vertical support of the hoist system superstructure.

The tailgate shall manually fold under the vehicle for travel and manually unfold for use.

The ramp shall taper down to ground level to facilitate loading with a wheeled handcart.

Platform loading area shall be of nonskid sheet steel. The tailgate shall have devices for holding the platform in stowed position for vehicle travel.

Controls shall be mounted outside the body on the curbside of the vehicle and shall include an electric control station with environmentally sealed connections, that the operator can reach easily while standing on the ground, or riding on the platform.

Tailgate lift operations shall be hydraulically metered, providing for raising and lowering without manual assistance. The lift platform extension shall be manually folded out. The tailgate shall be operated hydraulically through an electric driven hydraulic pump. All hydraulic cylinders shall be provided with flow restrictors in the down port of the cylinders to prevent the tailgate from falling rapidly in the event of a hydraulic system failure. The vehicle ignition switch or a separate switch in the driver’s compartment shall allow the driver to disconnect the power source to the tailgate. A 150-ampere minimum, automatic reset circuit breaker shall be furnished with the electric system of the tailgate, to protect the electric system of the vehicle. A minimum of 2-gage wire shall be furnished on the power cables for maximum operating efficiency and increased electrical component life. A rustproof enclosure shall be furnished to protect the pump motor from dirt and weather. Self-lubricated bearings shall be furnished on all load bearing rollers and hinges. All hydraulic lines shall be grommeted where they are routed through walls and supports and furnished with clamps for protection from damage.

The hydraulic tailgate operating instructions, the hydraulic fluid identification information and any caution notice shall be on a standard decal or plate from the supplier of that item. The decal or plate describing operation of the hydraulic tailgate shall be provided in close proximity to the hydraulic tailgate controls.

Rear bumper and additional rear end protection need not be furnished.

Hydraulic tailgates must conform to FMVSS-223 and 224.

3.1.9 PARTS LIST OR BOOK AND SHOP REPAIR MANUALS

One hard copy and one electronic version operator’s manual shall be packed with each vehicle. Two hard copy sets and one electronic version of maintenance and parts data along with any operation, maintenance and parts data for mounted or specialized equipment, shall be furnished, regardless of the number of vehicles the consignee is receiving. Example: if ten vehicles are shipped to a consignee, only two sets of the tech manuals mentioned above are shipped to the consignee; however, an operator’s manual shall be provided for each vehicle.

In addition, one hard copy and one electronic version of technical manuals consisting of operating, maintenance, and parts for the chassis and mounted equipment, shall be sent to the following address:

542 MSUG/GBMUDE

380 Richard Ray Blvd, Suite 104 Robins AFB, GA 31098-1640

3.1.10 SPARE TIRE ASSEMBLY

A spare tire assembly for the front axle shall be provided. The spare tire assembly shall be identical to those on the axle for which it is intended. The spare tire assembly shall include an inflated spare tire(s) mounted on the spare wheel(s).

3.1.11 SPARE TIRE CARRIER

A carrier for a spare tire assembly shall be provided. The carrier shall enable the safe removal and installation of the spare tire assembly from and to the vehicle and carrier without personnel positioning themselves or any part of their body under the spare tire assembly. Threaded fasteners, when used to secure the spare tire assembly in the carrier, shall be constructed of or plated with corrosion resistant material. The spare tire carrier shall be furnished on the vehicle undercarriage, where the tire assembly is easily accessible from the curbside of the vehicle.

3.1.12 EMERGENCY EQUIPMENT, EXTINGUISHER, TRIANGLES

Emergency equipment in accordance with FMCSR 393.95 shall be provided:

Fire extinguisher, minimum 10 B:C, as required in 395.95 paragraph (a)(1)(i).

Spare fuses as required in 393.95 paragraph (b).

Reflective emergency triangles meeting the requirements of 49 CFR 571.125 (FMVSS 125) as required in 393.95 paragraph (f)(1).

In addition, the cab shall be equipped with two portable fire extinguishers; each rated at least 2A-1B-C. One of the extinguishers shall be mounted on the outside of the cab on the driver's side on the front of the van body and the other inside the cab on the transmission “hump”. The extinguisher that is mounted outside of the cab shall be mounted away from potential fuel sources (fuel tanks, engine compartment, etc). The government shall approve the location of these two fire extinguishers.

3.1.13 PLACARD HOLDERS

Hazardous material placard holders in accordance with 40 CFR Part 172 shall be installed on each side and each end of the vehicle.

The following placards shall be furnished:

1.3C Explosive

1.4S Explosive

Flammable

Drive Safely

3.2 VAN BODY GENERAL

The van body overall dimensions shall be as follows:

Length of body = 240 in ± 1 in.

Inside width of body = 96 in + 2.0 in. – 0.0 in.

Inside height of body = 96 in + 2.0 in – 0.0 in.

3.2.1 VAN BODY

The body subframe, rear corner posts, rear header, rear crossmember, rear bumper and dock bumper shall be constructed of steel. Body, front posts, roof panels, rub rails or buffer sheets, side and front wall panels shall be constructed of aluminum. Roof bows and side posts shall be aluminum or galvanized steel. (see paragraph 3.2.11). The steel used shall be of the minimum gages specified for carbon steel; high tensile steel used may be two gages lighter weight in accordance with US Standard gages.

3.2.2 VAN BODY WIND DEFLECTION

An aerodynamically streamlined body front shall be incorporated into the design of the body to direct airflow around the sides and over the top of the van body. The construction shall be integral with the van body front wall, sidewalls and roof, giving a curved front radius.

3.2.3 VAN BODY SUBFRAME

Van body sub frame shall be welded steel construction, braced at all points of stress.

Crossmembers shall be full width, minimum 3 inches depth, of full channel, I-beam or equivalent section, steel construction, attached to longitudinal sills by welds on maximum 12 inches centers. When sub framing is a welded assembly, angle gussets (when used), crossmembers, longitudinal sills, and welded reinforcements (when used) shall be joined by weld for not less than 50 percent of the length of the contact edge(s).

Spacing of crossmembers shall be equal, ahead of, and to the rear of the wheels.

Longitudinal sills shall be constructed of structural steel channels, structural steel I-beams, formed steel channels or form rolled steel I-beams. Formed channel sills shall be reinforced with formed channel reinforcements within the sill. Formed channel reinforcements shall be provided at each subframe crossmember attachment point and at each chassis mounting point. Form rolled I-beam sills shall be high tensile 60,000 psi yield steel, not less than 4 inches high and not less than 3.190 pounds per foot.

Formed channel crossmembers, gussets, formed channel longitudinal sills and reinforcements shall be of not less than 7 gage (0.094 inch) steel. Extruded aluminum or steel side and front rails shall be furnished. When steel side and front rails (out-rails) are furnished they shall be of not less than 12 gage (0.1046 inch) steel. Design of the subframe shall permit low floor height, while providing tire chain clearance.

Understructure shall be rust proofed in accordance with FED-STD-297.

3.2.4 VAN BODY FRAMING.

Side and front post construction of aluminum or galvanized steel bodies shall be extruded aluminum and shall be not less than 1.125 inches in depth and 0.330 pound per foot when side and front wall posts are spaced 16 inch maximum centers. Side and front post construction shall be extruded aluminum and shall be not less than 1.25 inches in depth and 0.43 pound per foot when side and front wall posts are spaced on 18 inch maximum centers. Front corner posts, when used, shall be extruded aluminum and shall be not less than 1 inch in depth and 0.482 pound per foot. When front radius corners without front corner posts are used, the radius corners shall be of not less than

0.071 inch aluminum or 0.037 inch stainless steel, attached to the nearest side and front posts. The front structure shall be capable of withstanding a horizontal static load equal to 0.4 times the payload capacity of the vehicle without permanent distortion. Rear corner posts shall be provided and shall be of not less than 10 gage 0.1345 inch galvanneal or 12 gage 0.1046 inch stainless steel.

3.2.5 RESERVED

3.2.6 VAN BODY INTERIOR.

3.2.6.1 INTERIOR BODY WALLS

The interior of the body walls shall be lined with not less than 0.5 inch exterior grade plywood on the side and front walls, all full height. The plywood will be lined with minimum 0.125-inch aluminum sheeting on walls, side and front, all full height. The cargo van wall construction shall be strong enough to support shelving, carrying 500 Ibs every linear yard and attached to the vertical wall supports (shelving to be provided and installed by the end user). When steel roof bows are furnished, an isolating material shall be installed between the roof skin and the roof bows to prevent electrolytic action.

3.2.6.2 INTERIOR CARGO CONTROL TRACKS

Three tiers of Kinedyne model 43001, or equal, horizontal E track running the full length of the side walls and the full width of the front bulkhead shall be furnished on the inside of the cargo van body and shall be anchored to wall support structure (surface mount).

The rails shall be capable of supporting 500 pounds of cargo load during emergency stops. One tier of the E track shall be located 12 inches above the floor; a second tier shall be located three feet above the floor; and the third tier shall the located five feet above the floor; plus or minus 0.5 inch. A total of 64 E track fittings, Kinedyne model FE8301-1, or equal, shall be furnished.

Offering: E-track and fittings

Manufacturer: _____________________________________________

Model: __________________________________________________

3.2.6.3 ROOF SKYLIGHTS

The roof shall be furnished with four 12-inch diameter (actual clear lighting diameter)skylights, which shall be located in the front 2/3 of the van box. The skylights shall be arranged two on each side of, and symmetrical with, the longitudinal centerline of the roof. Skylight installation shall be leak free, allowing no leaks from snow and/or rain.

3.2.7 VAN BODY FLOOR

A diamond tread aluminum plate floor, minimum 0.25 in thick and an underlay laminated hardwood of not less than 1.125 inch thick, shall be provided for a van body. Wood floorboards shall be attached to the subframe at crossmembers with self-tapping, countersunk, corrosion-resistant screws.

Additionally, two rows of flush mount, fold down "D" tie-down rings shall be mounted in the floor. "D" rings, when in the folded-down position, shall be flush with the top of the floor (plus or minus .06 inch). The inside diameter of the "D" rings shall be no more than

1.50 inches. The street side row shall have eight (minimum) "D" rings located 30 inches (plus/minus 0.5 inch) from the interior side wall. The first ring in the street side row shall be positioned two feet (nominal) from the front bulkhead wall. The curbside row shall have six (minimum) "D" rings located 30 inches (plus/minus 0.5 inch) from the interior side wall. The first ring in the curbside row shall be positioned six feet {nominal) from the front bulkhead wall. The remaining "D" rings shall be evenly spaced (approximately 2 feet apart) and secured to the van body floor cross beams. Each "D" tie-down ring shall be capable of restraining 500 pounds of cargo load while operating the vehicle on highways and dirt/gravel roads.

3.2.8 SCUFF PLATE

A 12 inch high, 12 gage (0.1046 inch), smooth steel scuff plate, or an aluminum scuff plate of a thickness, providing an equivalent resistance to puncture, shall be installed on the front and side walls at the floor level. The entire scuff plate shall be treated or coated to resist corrosion (for steel) and need not be painted. The scuff plate shall be installed with corrosion-resistant countersunk screws, riveted, or welded to formed corner plates.

3.2.9 VAN BODY DOUBLE REAR DOORS

Double rear doors shall be provided for the van body, full width and height, with bracing to prevent sagging, and equipped with three cast steel, or equal, hinges per door. The door locking devices shall include not less than three bolts or latches, located at top, bottom and center of the door. Cam type locking devices may be furnished at the top and bottom of the door. The center locking device shall be provided with an operating handle and shall be installed to ensure positive closing under all operating conditions.

Provisions for the use of a padlock shall be furnished. The van body shall be equipped at the sides with catches for holding the doors in the fully open position. Hardware shall be the manufacturer’s standard. Rear doors shall conform to TMC RP 711.

Side catches shall provide a positive means of securing doors in a fully open position and capable of holding doors open in a 50 knot per hour wind without causing permanent deformation of the doors. The rear double doors shall be of sufficient strength to prevent bending or any deformation during opening and closing in 50 knot per hour winds. The curbside rear door shall be furnished with a 4 inch by 4 inch, top hinged trap door, located approximately one foot from the bottom and one foot from the hinged side of the door. The trap door material shall be the same material as the surface to which it is attached. The same door catch used on the rear doors shall be used on the trap door to hold in the open position. The trap door shall be furnished with a nylon block cable protector to protect cables as they are pulled through the trap door.

A rear license bracket shall be furnished and mounted on the lower portion of a rear door.

3.2.10 VAN BODY MOUNTING

3.2.10.1 BODY MOUNTING

Body shall be secured with U-bolts, twin studs, or brackets. Body shall be mounted in full accordance with the chassis and body manufacturer’s recommended practice.

3.2.10.2 U-BOLTS OR TWIN STUDS

When U-bolts or twin studs are used, there shall be not less than four U-bolts or twin studs per side each having 0.563 inch body diameter with 0.625 inch minimum thread diameter. Tieplates shall be at least 0.5 inch thick and a slight deformation upon assembly is permissible. The vehicle chassis frame shall be protected from crushing by using spacer blocks at each mounting point unless the mounting point is located at a full depth frame crossmember. Blocks shall incorporate a keeper strap or groove for the mounting bolt, and shall be of a width and thickness to assure retention. Two tieback straps shall be provided, one bolted to each side of the rear portion of the body subframe, to maintain body alignment on the vehicle chassis. Forward body mounting bolts shall be located to the rear of the tapered portion of the breaker strips.

3.2.10.3 BRACKETS.

When brackets are used, they shall be bolted to the web of the chassis frame rails. The body mounting brackets shall provide means for drawing down the body on the chassis rails, and provisions shall be made to prevent lateral shifting of the breaker strips.

When additional holes are required to secure the mounting brackets to the chassis frame rails, they must be located within the area of the rail, which is designated as being safe for drilling in accordance with the chassis manufacturer’s body builders layouts.

Attachments shall neither interfere with nor obstruct chassis components.

3.2.11 BODY EXTERIOR

The roof assembly shall be standard for the vehicle, and shall be constructed to ensure drainage. Roof support bow construction shall be extruded aluminum, or not less than 18 gage 0.0478 inch galvanized steel, not less than 1.38 inches in depth. When aluminum roof support bows are spaced on 24 inch maximum centers, the roof bows shall be not less than 1 inch in depth and 0.36 pound per foot, and the roof panel shall be not less than 0.032 inch aluminum alloy. When aluminum roof supports bows are spaced on 18 inch maximum centers, the roof bows shall be not less than 1 inch in depth and 0.38 pound per foot, and the roof panel shall be not less than 0.025 inch aluminum alloy. When steel roof support bows are used, they shall be spaced on not more than 24 inch centers and the roof panel shall be not less than 0.040 inch thick aluminum alloy. Body side panels shall be not less than 0.032 in. pre-painted aluminum alloy. Unless otherwise specified, the color of the pre-painted side panels shall be the manufacturer’s standard white. When a semi gloss or lusterless vehicle exterior color is specified, the side panels shall be painted to match that exterior color (see MIL-HDBK- 1223). Body side panels shall be removable to facilitate body repair. All roof and body seams and joints shall be weatherproof. The body front posts and top front rail shall have a radius of not less than 4.5 inches. All body and rub rails shall be extruded aluminum. Rub rails or buffer sheets extending outwards beyond the body skin shall be provided on both sides of the body. The rub rails or buffer sheets shall be permanently attached, or shall be an integral part of the exterior of the body at the floor line.

3.2.11.1 GROUNDING BOXES

An enclosed galvaneal steel ground box shall be mounted on the street side at the rear of the van body so that a person standing on the ground can reach the ground wire. The ground box shall contain an independently operated, heavy duty automatic rewind cable reel with minimum 50 feet of 0.125 inch stainless steel aircraft cable and minimum 100 amp ground clamp. The ground cable box door shall be hinged on the left side and shall not require keys for opening and closing. A ground clip retainer shall be attached to the inside of the hinged door. When the door is opened, the clip shall be easily accessible.

The ground cable box door shall be furnished with a 4 inch by 4-inch (minimum) opening to allow the ground cable and clip to pass through. The opening shall be furnished with roller guides to prevent abrasion to the cable when in use. The 4-inch by 4-inch opening shall be fitted with a weatherproof trap door, with a positive closing latch and handle. The trap door shall be of the same material as the material to which it is attached. The ground box door and trap door shall be sealed with neoprene bulb type automotive door edge seals, with the ends of the sealing strips on the bottom of the doors. All hinges and door hardware shall be stainless steel.

3.2.11.2 STORAGE BOXES

Two minimum 14 Gage galvaneal steel storage boxes shall be mounted to the chassis frame rails, one on each side. The street side box shall be 60 inches in length, 31 inches deep and 24 inches high (plus 1 minus 1.25 inch). The box shall be of double door design, latching in center and incorporate T-handle door latches and spring type door hold open devices and shall not require keys for opening and closing. The curbside box shall be 36 inches in length, 31 inches deep and 24 inches high (plus / minus 0.25 inch). The box shall be of double door design, latching in center and incorporate T-handle door latches and spring type door hold open devices. Both boxes shall be mounted forward of the rear wheels. Both boxes shall be reinforced and mounted to the frame such that there is no flexing, or “oil canning” of the boxes’ mounting structure or sheet metal. The storage box doors shall be sealed with neoprene bulb type automotive door edge seals, with the ends of the sealing strips on the bottom of the doors.

3.3 HEATERS

Two electrical heaters shall be furnished. The heaters shall be mounted to the front wall and be installed with controls facing outward towards the body walls. Heaters shall be Marley Engineered Products brand QMark® model LFK404, 208/240 volts, 60 Hz, minimum 3000 watts, or equal.

Offering for: Heaters

Manufacturer's Name __________________

Brand and/or Number __________________

3.4 ELECTRIC CHAIN HOIST AND MOUNTING FRAME

The van body shall be furnished with an electrically operated 11O V AC single phase 1000 pound capacity (minimum) monorail chain hoist, mounted on an inverted steel "U" frame and secured in the van body. The steel frame shall be designed and installed so that it will support the traveling “I” beam, hoist, and the hoist’s rated load with no measurable deflection in any direction. The frame shall be secured to the van body through the floor only, and shall be designed with sufficient bracing and gusseting to assure there is no side-to-side or forward-and-aft movement of the frame while roading or while in use. There shall be no deformation of the floor or van body at the attachment points of the frame. The frame and “I” beam shall be completely primed and painted with gray urethane paint, Dupont Imron® 5000, or equal, before final installation of the frame. Surface preparation of the frame before painting shall be in accordance with the paint manufacturer’s instructions. The hoist shall be a Yale model KEL-B-1/2- 45EB16S1 with Catalog No. 81 trolley, or equal. The hoist shall have a handle to move it along the "I" beam. The hoist "I" beam shall be a minimum of 4 inches in depth with flange width between 2.625 and 4.625 inches and capable of being extended 10 feet (minimum) beyond the rear of the van body. The beam shall pivot and have 15 inches lateral movement from the center of the rear door opening to either side of the centerline. The "I" beam shall be furnished with three lateral locking positions each side of the centerline, utilizing quick release pins for securement. The extendible "I" beam shall have a minimum of two handles located on the forward end of the beam; one will run in the direction of the beam and one will run opposite the beam. There shall be a minimum of 68 inches clearance between the van floor and the hoist hook when the hoist is in the full "up" position. The hoist pendant shall be push-button type with deadman type controls. The pendant cable shall be a minimum of 12 feet long, to enable operation of the hoist while standing at ground level. A storage bracket attached to the hoist “I” beam shall be furnished for stowing the pendant control. The hoist AC power cable shall have an automatic take-up reel, Reelcraft model no. L-4545-12-3-7, or equal, and be mounted as close as possible behind the hoist on the front wall of the van box. The hoist chain shall be furnished with a Bullard hook assembly and shall be capable of extending 45 feet measured from the bottom of the "I" beam. A chain storage box shall be attached to the hoist to stow excess chain. The hoist shall have a locking device that utilizes a quick release pin that will enable the operator to position and secure the hoist every 4 inches along the full length of the “I” beam. One additional locking position shall be furnished as far rearward as possible for storage of the hoist when traveling. A cradle to stow the "I" beam when in the forward most position shall be provided on the front wall of the van box and the "I" beam shall be secured to the cradle with a snap-lock type pin. The cradle shall be attached to an 18 inch by 24 inch steel plate of minimum 0.188 inch thickness to protect the front wall of the van box. Hoist power cable supports shall be provided to prevent sagging of hoist power cable when hoist is deployed to aft end of trolley I-beam. The cable supports shall have no sharp edges that could damage the power cable. The hoist power cable shall be furnished with a strain relief system and shall be designed to avoid bare metal to rubber insulation contact.

Offering for: Chain hoist, trolley, and take up reel

Manufacturer's Name ____________________________________________________

Brand and/or Number ____________________________________________________

3.5 STORAGE CABINET

A four drawer (minimum) heavy duty storage cabinet (capable of supporting 35 pounds per square foot without permanent deformation) equipped with individual drawer latch locks (not key locks) shall be provided. The cabinet shall be mounted by the end user, but secured in the van for shipment. The cabinet shall be a Stanley Vidmar Cabinet, model DWMT3203MR, or equal.

Offering for: Storage cabinet

Manufacturer's Name ____________________

Brand and/or Number ____________________

3.6 NITROGEN GAS CYLINDER STORAGE RACKS

Wall brackets shall be furnished to hold three (3) 9-inch diameter compressed nitrogen gas cylinders. The brackets shall be Air Products model 24-1500 wall brackets with 54

in. straps, or equal. There shall be six (6) brackets furnished (two per cylinder). These brackets shall be shipped loose and installed by the end user.

Offering: Gas cylinder storage racks

Manufacturer: _____________________________________________

Model: ___________________________________________________

3.7 POWER CABLE REEL

An encased power cable reel shall be mounted on the curbside in the front of the van body. The cable reel shall be a manual pull, spring return Gleason Reel Corp. model S28802-612-13-4, or equal, furnished as follows:

With Gleason part no. 012087 nylon roller guides installed on the reel

With Gleason part no. 012090 dog and ratchet assembly installed on the reel

With Gleason part no. 037537 ball stops

The power cable reel encasement shall consist of a tubular frame mounted to the floor in the curbside front comer of the body with a 3/16-inch thick sheet aluminum cover on all sides and top. To allow for ease of service the aluminum cover shall be removable as one unit with the disconnection of a minimum amount of fasteners. The encasement shall be furnished with a minimum 6 inch by 6 inch opening that allows the power cord to be pulled from and returned to the reel through nylon rollers that protect the cord from abrasion when pulled from any direction. A retaining clip shall be furnished near the opening to allow for securing the plug and preventing it from passing through the encasement to the reel. The dimensions of the encasement shall be 34±0.5 inches wide by 48±0.5inches long by 32±0.5 inches high.

The cable reel shall be wired to the circuit breaker box located inside the van body. The cable reel core shall be no smaller than 24 inches in diameter and the cable shall be rolled off the bottom of the cable reel. One hundred (100) feet of Siemens brand Cordaflex® power cable #6AWG, part no. 5DH3-458 (Anixter Co. part no. 4EC-O606-

05) six conductor, three phase wire, or equal, shall be installed on the reel.

Offering for: Power cable

Manufacturer's Name_____________________

Brand and/or Number_____________________

The loose end of the power cord shall be connected to a cannon plug, Pyle-National Star-Line® catalog no. ZPLM-1220-337PN. No substitution or “equal” shall be allowed.

Amphenol distributors who may provide this plug, with phone numbers, are as follows:

Offshore Marine-800-506-9473

Wholesale Electric-800-486-8563

Warren Electric-713-236-0971

The cable shall be connected to the plug as follows:

The ground wire shall be connected to pin #1, neutral to pin #2, hot to pin #3, hot to pin #4, hot to pin #5 as viewed from the front, reading in a clock-wise position. The #6 conductor wire shall be dead wire. The keyway alignment on the cannon plug shall be as follows: looking at the plug head on, one keyway shall be at the 12 o'clock position and the second keyway shall be at the 3 o'clock position. This will place the #1 pin at approximately 1 o'clock position and the #2 pin at the 3 o'clock position.

3.8 POWER CABLE ACCESS DOOR IN VAN WALL

A 24-inch by 24-inch (nominal) door shall be furnished in the front of the curbside wall as close to the floor as practicable and adjacent to the power cord opening in the power cord reel encasement. The door shall be hinged on the right side and shall be furnished with a positive securing handle and latch and shall not require keys for opening and closing. The door opening shall be furnished with a heavy duty rubber bulb type automotive neoprene gasket that assures for a waterproof seal when in the closed position. The 24-inch by 24-inch door shall be furnished with 4-inch by 4-inch (minimum) opening with edge guard, as close to the bottom as practicable, to allow the cannon plug to pass through for hook up. The 4-inch by 4-inch opening shall be fitted with a weatherproof top hinged trapdoor, with a positive closing latch and handle. The trap door shall be of the same material as the material to which it is attached, and shall be furnished with a latch to secure the door in the open position. A retaining clip shall be furnished on the inside of the 24-inch by 24-inch door for securing the cannon plug, when not in use.

3.9 LIFE LINE ATTACHMENT POINTS.

The van body shall have four life line attach points on each side of the van, for a total of eight. One shall be located on the rear exterior of the van box at a height of 45.0± 1.0 inches from the ground. The remaining three shall be located inside the van box attached to the hoist superstructure. One shall be located at a height of 9 inches (plus or minus one inch) above the van floor and the other at a height of 65 inches (plus or minus one inch) above the van floor. Both attachments shall be located on the rear superstructure upright. The remaining attachment shall be located approximately mid-ship of the van box on the superstructure upright at a height of 65 inches (plus or minus one inch) above the van body floor. The life line attachment points shall each be capable of supporting a minimum deadweight of 5,400 pounds. A metal plate shall be furnished adjacent to each life line attach point identifying its function.

3.10 LADDER RACK

A ceiling mounted ladder storage rack shall be furnished for an 8 foot long "A" frame ladder and shall not interfere with the lateral movement of the hoist monorail from side to side. The dimensions of the ladder are as follows:

Width at top……………….14 inches Width at bottom…………..28 inches Thickness when folded…..7 inches Height………………………8 feet

The ladder rack shall be furnished loose.

3.11 ELECTRICAL

3.11.1 12-VOLT DC LIGHTING

3.11.1.1 VAN STOP, TAIL, TURN, AND CLEARANCE LIGHTS

Stop, tail, turn and marker lights shall be LED style lights. The rear stop, tail and turn lights shall be protected by stainless steel wire mesh covers.

3.11.1.2 VAN INTERIOR 12 VDC LIGHTS

Eight (8) shielded 12V DC floodlights, furnished with trapezoidal fixtures and tungsten halogen bulbs shall be mounted on the sidewalls, four on each wall, located as follows:

Four lights on each side of the van mounted 85 inches from the floor to the bottom of the light fixtures.

From the front wall of the van, the lights shall be mounted at 36, 84, 131, and 177 inches (measurement to the center line of the fixtures).

Two 3-way switches, controlling all DC lights shall be furnished. One switch shall be located on the rear of the curbside wall, near the floor, recessed to prevent damage by cargo or equipment and shall be accessible to an operator standing on the ground at the curbside of the vehicle. The other switch shall be located in the cab with an indicator light. DC lights shall be furnished with power by the vehicle electrical system.

3.11.2 VAN INTERIOR 115 VAC LIGHTING

Two swivel mounted 115 VAC halogen floodlights, Phoenix Products Company, Inc.

Sturdilight floodlight model 120/56/300 with PAR 56 500 watt Halogen medium flood bulb, or equal, and shall be installed in the upper right and left rear corners inside the van box, as near the rear as possible. Each light shall have a switch and a handgrip.

Offering for: 115 VAC floodlights

Manufacturer's Name____________________________________________

Brand and/or Number____________________________________________

Eight 100 watt, 110 VAC incandescent light fixtures shall be mounted on the side walls, four on each wall, located adjacent to the 12 V DC lights described in 3.11.1.2 above, and wired through the circuit breaker panel. These lights shall be switched from a weather proof and guarded light switch located on the street side wall accessible form the ground. The light fixtures shall be Lumark 100 watt Micro-Pac mini wall fixtures, model HPMP-PC-100-120-LL, fitted with 100W High Pressure Sodium lamps and WG/GP-GS wire guard, or equal. The lights shall provide full illumination of the cargo area during darkness.

Offering for: 115 VAC light fixtures

Manufacturer's Name____________________________________________________

Brand and/or Number____________________________________________________

3.11.3 BREAKER PANEL BOX

A 3-phase circuit breaker panel in a NEMA 1 enclosure box shall be furnished on the curbside wall and shall contain six (6) separate breakers-one each for the lights, receptacles, crane, and one each for the heaters with a 60 amp main breaker to turn off all power. A wiring diagram shall be furnished.

3.11.4 DUPLEX OUTLETS

Two OEM/Industrial Grade Nema 5-20R duplex 2-pole, three wire grounding GFCI protected115 V AC/20 amp weather protected electrical receptacle outlets shall be furnished and wired through the circuit breaker panel. One shall be located on each side of the cargo box, as far to the rear as possible and accessible to the operator while standing on the ground. The receptacles shall be Arrow-Hart catalog number GF5342H, or equal, with Arrow Hart catalog no. 4501 or 4502 weather protective cover, or equal.

Offering for: Duplex receptacles

Manufacturer's Name_________________________________________________

Brand and/or Number__________________________________________________

3.11.5 WIRING

All 12 volt DC wiring shall be in accordance with the applicable requirements of SAE J1292. All wiring shall be copper stranded and protected by SXL, GXL, or Hypalon type insulation. All in-line wiring connections shall utilize locking lip seal type connectors.

Wiring shall be routed in a flexible loom or conduit. All fasteners, conduit, and conduit fittings shall not exhibit electrolysis with adjacent materials. All wires and looms shall be routed to assure that they do not abrade or be damaged by any part of the chassis, engine, or body. Grommets or electrical bulkhead fittings shall be furnished when wires or harnesses pass through walls or structural members. All conduits, looms and wires shall be secured to the body or frame using insulated metal cable straps. Wiring terminals shall be crimped to assure that they grip both the wire insulation as well as the conductor. Terminal attachments shall comply with SAE J163, and the terminations themselves must comply with SAE J561 (ring and spade types), SAE J858 (blade type), or SAE J928 (pin and receptacle type). Circuit protection shall be accomplished by the use of circuit breakers, fuses, or fusible links conforming to SAE specifications. All switches, relays, connectors, and all other electrical components shall be rated for a minimum of 125 percent of the maximum current for which the circuit is protected.

Environmentally sealed switches shall control 12-volt systems lighting systems.

Wire sizes and circuit breaker ratings shall comply with the following:

Wire Size (minimum) Circuit Breaker Rating (maximum)

18 AWG 5 AMPS

16 AWG 10 AMPS

14 AWG 15 AMPS

12 AWG 20 AMPS

10 AWG 30 AMPS

8AWG 50 AMPS

The 115 V AC wiring shall utilize stranded wire in armored non-metallic sheathed flexible cable, “Type SO” or better, rated at 600V and 60 deg C, covered with a minimum 149 deg C (300 deg F) flame retardent wire loom, or approved wire in conduit.

All 115 volt wiring shall be in accordance with the National Electrical Code.

Internal and external wiring methods, appliances, and weatherproof receptacle covers shall be suitable for wet conditions in accordance with the National Electrical Code.

Ground fault circuit-interrupter protection in accordance with the National Electrical Code, shall be provided.

3.12 MISCELLANEOUS REQUIREMENTS.

3.12.1 WORKMANSHIP.

A. Vehicles shall be free from defects that may impair their serviceability or detract from appearance.

B. All bodies, systems, equipment and interfaces with the chassis shall be done in accordance with the OEM ’s Body Builders Book. Whenever dissimilar metals are used, they shall be insulated against corrosive action.

C. All components will be new. Defective components shall not be furnished.

Parts, equipment, and assemblies, which have been repaired or modified to overcome deficiencies, shall not be furnished without the approval of the purchaser.