191NLE19N0047.pdf

RESPONSE TO REQUEST FOR INFORMATION NOTICE (191NLE19N0047)

U.S. Department of State

Bureau of International Narcotics and Law Enforcement Affairs

INL Costa Rica

INL/Costa Rica Tool Truck

Request For Information (RFI) #: 191NLE-19-N-0047

I. REQUEST FOR INFORMATION SUBMISSION NOTICE

This Request for Information (RFI) will be used to identify potential sources that are interested in and capable of performing the work described in this “Draft” Statement of Work (SOW). In accordance with FAR 15.201(e), responses to this notice are not offers and cannot be accepted by the Government to form a binding contract. This RFI is issued solely for conducting market research, information and planning purposes and does not constitute a solicitation or obligation on the part of the Government. Neither unsolicited proposals nor any other kind of offers will be considered in response to this RFI. No reimbursement will be made for any costs associated with providing information in response to this announcement and/or any follow-up information requests.

The purpose of this RFI is to communicate and solicit feedback from industry on the “Draft” version of an upcoming overseas requirement for INL/Costa Rica Tool Truck. Contractors shall provide company capabilities and pictures (if able). The NAICS Code for this requirement is

336112 - Light Truck and Utility Vehicle Manufacturing.

Please do not provide generic capability statements, as they shall add no value to this RFI. The

Government is seeking specific information in conjunction with the specifications of this requirement.

The page limitation for responses is 25 pages.

All responses shall be submitted in writing via email to Patrick Jones (Contract Support

Specialist) at JonesPR@state.gov, no later than 11:00 AM, EST on August 12, 2019.

In order to participate in the resulting RFQ and to be eligible for an award, the proposer must have (i) a current CAGE Code, (ii) a DUNS#, (iii) be registered to do business with the

Government of the United States in the System For Award Management (SAM) and not be on the Excluded Parties List: https://www.sam.gov

II. COMPANY INFORMATION

Company Name

Address

DUNS Number

Company Website

POC Name

Phone

Email mailto:JonesPR@state.gov https://www.sam.gov/

III. SOCIOEONOMIC STATUS

a. Provide information pertaining to your company’s socio-economic status for federal procurement programs (small, HUBZone, 8(a), Women-owned, veteran-owned, etc.)

under NAICS code 336112.

The size standard for NAICS 336112 is 1,500 employees. Unless the SBA has granted a class waiver of the NMR for a particular product, the company will either be required to be the manufacturer of the products offered or qualify for the procurement as a

“nonmanufacturer”. In accordance with FAR 19.102(f), the applicable size standard for a

“nonmanufacturer” is 500 employees.

Response:

b. Is your company the manufacturer of the product included in Attachment 1?

c. If your company is not the manufacturer, identify the manufacturers’ names, addresses, DUNS numbers, and other pertinent information. Are all manufacturers U.S. small business concerns?

d. If the manufacturer is not a US small business concern, has the SBA issued a class waiver of the non-manufacturer rule for the product? If so, please identify the applicable class waiver(s).

IV. PRODUCTS AND SERVICES

a. Provide a list of the product(s) sold by your company meeting the requirements of this

RFI. Where a particular standard is included in the RFI, address your company’s product compliance with said requirements. Please note that unless explicitly stated all products in Attachment 1 will be solicited on a brand name or equal basis.

b. Is your company an authorized seller of the above-mentioned product(s) in Costa Rica? If so, what business licenses does your company possess in Costa Rica?

c. What areas of Costa Rica does your company service? Briefly describe your current logistical capabilities in Costa Rica.

d. Provide a brief description of your corporate experience in Costa Rica and Latin

America.

e. Are the products sold by your company covered under warranty in Costa Rica? If so, what is the length of the warranty offered? Are repairs handled in country?

f. Does your company provide training in Spanish? If so, is training accomplished via

Spanish speakers or via the use of translators?

g. Are equipment manuals provided in Spanish?

h. Would your company need to subcontract any part of the work? Please explain.

V. EXISTING CONTRACTS

a. List any existing contract vehicles through which the US Department of State can access your company’s products and services (i.e. GSA FSS, IDIQs, etc.)

VI. RECOMMENDATION

a. Did your company identify any areas in the draft specifications that present excessive risks, restrictions or other concerns? If so, please provide detailed information and suggested mitigation.

U.S. Department of State

Bureau of International Narcotics and Law Enforcement Affairs (INL)

DRAFT STATEMENT OF WORK

INL/San Jose, Costa Rica Tool Truck

ATTACHMENT 1

Contents

1.1 Background

1.2 Scope

1.3 Period of Performance

1.4 Program Support Organization

1.5 Government Management Organization

2.0 APPLICABLE DOCUMENTS

2.1 Order of Precedence

3.1 General Requirements

3.2 Technical Specifications

3.3 Body Requirements

3.3.1 Service Body

3.3.1.1 Service Body Interior Storage

3.3.1.2 Service Body Exterior Compartments

3.3.2 Service Body Mounting

3.3.3 Tools

3.3.4 Fuel System

3.3.5 Payload Capacity

3.3.6 Wheel and Tires

3.3.7 Rear Bumper

3.4 Emergency Lighting/Siren

3.4.1 Security System

3.4.2 Back- up Alarm and Back-up Camera

3.5.1 First Aid Kit

3.5.2 Fire Extinguishers

3.6 Electrical System (110/120 VAC and 12 VDC)

3.6.1 110/120-Voltage AC (VAC) System

3.6.1.1 110/120 VAC Exterior Outlets

3.6.1.2 110/120 VAC Interior Outlets

3.6.1.3 110/120 VAC Flood Lighting System

3.6.2 12VDC Dome Lamps

3.6.3 12VDC Vehicle Body Lighting

3.7 Generator

3.7.1 Generator Compartment

3.8 Deep Cycle Batteries

3.8.1 Battery Isolator

3.8.1.1 Battery Charger

3.8.1.2 Shore Power

3.8.2 12 Volt Systems

3.9 Air Compressor System

3.9.1 Air Compressor Service Disconnect

3.10 Trailer Towing Package

3.10.1 Trailer Electrical Connector

4.0 MISCELLANEOUS REQUIREMENTS

4.1 Markings, Data Plates

4.1.1 Paint, Finish, and Color

4.1.2 Interior Information Decals

4.2 Operators, Servicing, and Parts Manuals

4.3 Drawings and Weight Calculations

4.4 Workmanship

4.5 Externally Threaded Fasteners

4.6 Government Acceptance Testing

4.6.1 Water Spray Test

4.6.2 Generator Load Test

4.6.3 Pre-Service Inspection

4.6.4 Road Test

4.6.5 First Article Test

4.6.6 Drawings and Weight Estimations

4.6.7 Additional Contractor Requirements

4.7 DHS 4300A and Section 508 Clauses

5.0 TECHNICAL MANUALS

5.1 Operator’s Manual

5.2.1 Warranty Corrective Maintenance

5.3 Technical Review Meetings

5.4 Warranty

5.4.1 Reporting

5.4.2 Corrosion Control

5.5 Quality Assurance and Testing

5.5.1 Quality Assurance

5.5.2 Testing

5.5.2.1 Acceptance Test Plan

6.0 INTEGRATED LOGISTICS SUPPORT

6.1 Technical Documentation

6.2 Accessibility

6.3 Spares

7.0 DOCUMENTATION DELIVERABLES

Appendix 1 Acronyms List Appendix 2 Tool List

1.0 PURPOSE

The purpose of this procurement is to provide Costa Rican CET (Contraband Enforcement Team with a mobile, intrusive inspection capability at U.S. land and sea Ports of Entry (POEs). The Tool Truck is used by Interdiction Officers to examine hidden areas/compartments for concealed contraband. The tool trucks provide the Officers with a mobile tool system that provides the electrical and mechanical tools necessary to conduct intensive examinations.

1.1 Background

INL San Jose is committed to assisting the Costa Rican Government, specifically the Ministry of Public Security through their Uniformed Police Force (Tactical Intervention Team). Ministry of Public Security teams are combating drug trafficking, organized crime and entering high risk and violent communities.

INL/San Jose is supporting the efforts of the security forces in Costa Rica by providing equipment, technology and training. Costa Rican law enforcement institutions continue to make progress in combatting the drug trade and law enforcement in high risk areas in the country.

1.2 Scope

The Interdiction Technology Branch (ITB) under the Laboratories & Scientific Services Directorate (LSSD) assisted in the recommendation of similar equipment currently used in the U.S. to perform these tasks. Office is tasked with the procurement of Tool Trucks that can accommodate a minimum of 4 people, feature a chassis with a service body conversion, dual rear wheels, a heavy-duty pintle and tri-ball trailer towing system with an electronic trailer braking interface.

The following requirements outline the technical specifications for the Non- Intrusive Inspection (NII) Tool Truck acquisition..

1.3 Period of Performance

The ordering period is one (1) year from date of award or effective date of option exercise. The effective period begins at award and ends at completion of the last active order, or the last day of the ordering period, whichever is later.

One with option of two in the near future

1.4 Program Support Organization

This initiative will be managed by the INL Office in San Jose, Costa Rica.

1.5 Government Management Organization

Management of this initiative will be accomplished through the INL San Jose for the purchase, delivery, and acceptance of tool trucks. The Contractor shall coordinate with the Contracting Officer’s Representative (COR) to ensure successful system deployment. The exchange of technical data and the resolution of any interface issues will be facilitated by and through the COR.

2.0 APPLICABLE DOCUMENTS

1. Occupational Safety and Health Standards (OSHA), 29 CFR 1910 (Refer to http://www.osha.gov/)

2. National Fire Protection Association (NFPA) 79, Electrical Standard for Industrial Machinery

3. National Fire Protection Association (NFPA) 70B, Recommended Practice for Electrical Equipment Maintenance

4. American Society of Mechanical Engineers (ASME)/American National Standards Institute (ANSI) B18.18. Inspection and Quality Assurance for general purpose fasteners

5. Technical and Maintenance Council (TMC)-RP 803A – Pre-Service Vehicle Inspection (Published by the Technical and Maintenance Council of the American Trucking Association)

6. American National Standards Institute - ASC 14.5-2007 - Portable Reinforced Plastic Ladders

7. Society of Automotive Engineers (SAE) J2202 Heavy Duty Wiring Systems For On Highway Trucks

8. SAE J429 Mechanical and Material Requirements for Externally Threaded Fasteners

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

10. SAE J163 Low Tension Wiring and Cable Terminals and Splice Clips

11. SAE J561 Electric Terminals-Eyelet and Spade type

12. SAE J858a Electric Terminals-Blade type

13. SAE J928 Electric Terminals-Pin and Receptacle type

14. Telcordia; IEC (IP); MIL-STD-810G Rain Exposure; NEMA: RTCA/DO-160

15. SAE J595 Directional Flashing Optical Warning Devices for Authorized

Emergency, Maintenance, and Service Vehicles.

16. SAE J1292_201604 Automobile and Motor Coach Wiring

17. Federal Motor Vehicle Safety Standards (FMVSS)

18. Costa Rica Contraband Enforcement Team http://www.osha.gov/)

2.1 Order of Precedence

In the event of a conflict between the text of this Statement of Work (SOW) and the references cited above, the SOW takes precedence. Nothing in this SOW, however, supersedes applicable state and federal safety laws and regulations or the requirements set forth in the Contractor’s (vehicle manufacturer) Bodybuilders and Incomplete Vehicle Manuals.

3.0 REQUIREMENTS

The Contractor shall perform all tasks associated with this SOW as specified.

The Tool Trucks shall be delivered to INL San Jose. Tasks include system fabrication, integration, assembly, and delivery.

US EMBASSY SAN JOSE

DIPLOMATIC CARGO

AVENIDA 0 CALLE 120

PAVAS, COSTA RICA

3.1 General Requirements

The Contractor shall perform all work necessary to fabricate, assemble, deliver, and provide logistics support, as specified, for the Tool Trucks to result in the Tool Trucks being a turnkey system.

3.2 Technical Specifications

The Tool Truck specifications shall include, but not be limited to, the following:

Chassis:

o The chassis shall be a new current model year truck with capacity of at a minimum of 4 passengers o Shall be 4x4 (4 Wheel Drive) o Special Rating: Gross Combined Vehicle Weight (GCWR) Limited to 25,999-lb Gross Vehicle Weight Rating (GVWR) o Engine Fuel: Diesel o Engine block heater on all trucks o Automatic Transmission o Paint: Paint Schematic, PT-1 Single Color: White

Paint Type: Base Coat/Clear Coat o Winch, Front Bumper: Full Width, Aerodynamic, Steel with bumper winch of 8000lbs pulling power or better. (100 foot of 5/16” wire rope or better) o Air Compressor: 11 Cubic Feet per Minute (CFM), or better o Parking Brake, Vehicle using hydraulic brakes shall have power assist brakes o Electric Trailer Brake/lights: Accommodation Package to Rear of

Frame; for separate Trailer Stop, Tail, Turn, Marker Light Circuits;

Include Electric Trailer Kit and Controller; Include environmentally protected trailer connecting sockets. Trailer electric connector shall be standard commercially available 7-Way environmentally protected connector. The trailer interconnector shall be mounted in such a manner as to prevent damage when loading or offloading during system delivery and regular use.

o Battery System: Maintenance free two (2) 12 Volt batteries with a minimum 1100CCA combined total o Fuel/Water Separator: Integral to Fuel Filter, Attached to Engine (If required) o Fuel Tank: 40 U.S. Gallons or greater o Clearance/Marker light: Five (5) Flush mounted o Fog Lights: forward mounted or equivalent o Wheel, Spare: Full size o Vehicle Jack o Front and rear mud flaps shall be installed to control wheel splash o Two (2) electronically controlled side mirrors with breakaway capacity

Truck Cab shall include:

o Accommodate a minimum of 4 people, crew cab o Headlight Dimmer Switch o Cruise Control: Electronic o Floor Covering: rubber (floor mats to be included) o All Glass windows tinted except for the windshield.

o One (1) Grab handle, passenger side, cab interior.

o Two (2) Grab handles, one on each side of cab interior for rear seating.

o If the vehicle entry door sill is above 17 inches, then a step or running board assembly shall be included on both sides.

o 12 VDC vehicle power outlet o Gauge Cluster English Electronic Speedometer includes:

Gauge Cluster (5) Engine Oil Pressure (Electronic), Water

Temperature (Electronic), Fuel (Electronic), Tachometer

(Electronic), and Voltmeter o If the vehicle is equipped with a turbo system, then a separate gauge to monitor the turbo system shall be installed.

o If the vehicle has multiple fuel tanks, then a means to monitor the second tank shall be available by either a switchable fuel gauge or dedicated gauge for the second tank.

o If the vehicle is equipped with Diesel Exhaust Fluid

(DEF), then a means to monitor the DEF level shall be installed.

o Odometer display: Miles and Trip Miles o Warning System: Low fuel, Low Oil Pressure, High Engine Coolant

Temperature, Low Battery Voltage, and DEF low level warning.

o Seat, front bench, full width; includes Seat Belt two (2), 3-point shoulder belts for driver and outer passenger and one (1) lap belt for center passenger o Seat, rear bench, full width; two Integral outboard headrest, includes Seat Belt two (2), 3-point shoulder belts and one (1) 2-point lap belt in center seat is applicable. (center position) o Heater with defroster o Dome Light, door activated, timed dimming o Sun Visor (2) o Air Conditioning o Power Steering o Power Door Locks o Power Windows o Power Mirror adjustment

3.3 Body Requirements

3.3.1 Service Body

The service body shall fit the chassis as specified in this section and shall be galvanneal steel body shell and roof shall also be made of steel.

The finished interior dimensions of the truck bed enclosure (Service Body) shall at a minimum have an interior floor width of 48 inches, an interior height of 72 inches (Measured from roof support rib or lowest point to the floor), and a rear door clearance height of 60 inches and overall width of 90+ inches and length of approximately 108 inches. A drawing of the vehicle shall be provided by the Contractor showing that the body constraints can be met as well as the placement of all equipment with hold down features. The body shall be equipped with the following options:

Service Body a minimum of 48 inches wide floor and a minimum of 72 inches interior height

Rear door clearance height at least 60 inches

Rear door clearance width at least 40 inches

Service body rear entrance deck height: no higher than 45 inches with an ideal height of 37 to 40 inches.

Body width 90 inches

Body length approximately 108 inches

Three (3) 20 inches deep compartments per side

Two (2) full length Shelves inside

Side hinged swing out rear doors (two) with solid stainless steel hinges and with pneumatic arms

Installed entry grab handle on both sides in rear cargo area

Installed, durable metallic roof vent with interior opening/closing mechanism

Master locking system for side compartments, mechanical.

Shall have an additional master locking system for the rear doors with padlock capability.

Alarm system for the service body doors; both audible and visual

Pull out trays in both horizontal compartments

Vertical compartment slide (one each side)

Rear Steel bumper with step plate (antiskid) o In the event the rear service body floor is above the aforementioned

37 inches the vendor shall install fold down step assemblies for easier access.

Minimum of 4 LED lights to provide illumination for entire interior of service body

Heavy duty toolbox in driver’s side front compartment with 11 drawers per the tool inventory.

Mechanic’s vice: 5 inch minimum jaw width

Flush mount LED light kit; LED light package shall be mounted to illuminate each shelf, must be mechanically affixed to service body by means of hardware. Use of adhesive material is not acceptable.

One (1) portable 48 inches long by 20 inches deep work table shall be approximately 30 inches above body floor when erected. It shall be capable of being folded down to conserve space and capable of supporting a minimum of 100 lbs. when in use.

Tool drawers shall be no higher than 58 inches from the ground.

The Contractor shall ensure the body kit is built to projected design. The Contractor shall correct any part numbers or option omission to build a complete body. The rear departure angle of the completed vehicle shall not be less than 10 degrees. A rain gutter shall be furnished above the rear doors, extending 2 inches past the edge of the door. Mud flaps shall be installed behind the rear wheels of the vehicle to control wheel splash. Final body assembly shall be reviewed and approved by the Government at the vehicle design review in accordance with Costa Rican Riteve specifications..

3.3.1.1 Service Body Interior Storage

The equipment installed in the service body shall be secured to prevent shifting during vehicle movement, yet still allowing for easy removal. The method of securing tools shall not be so unique that it will require modification to hold replacement equipment, components, and tools. If strapping is used; all attachment points shall have oversized screw and washer assemblies to prevent retainers from detaching from the mounting points. Equipment and tools locations shall be marked for easy identification and replacement of tools and equipment.

Final system shall be reviewed and approved by the Government at the vehicle design review.

A Contractor-supplied fiberglass, platform ladder (type 1A-Extra Heavy Duty) shall be provided and secured inside the service body. The ladder must meet ANSI Standard A14.5-2007.

The service body (both exterior/interior) and exterior compartment interiors shall be painted to match the manufacturer chassis color.

See Appendix #2 for recommendations for equipment placement.

3.3.1.2 Service Body Exterior Compartments

There shall be a minimum of six (6) exterior compartments, three (3) on each side of the service body, furnished as follows:

Driver’s (street) side from front to rear:

o Tool compartment with drawers (for small tools) a minimum of eleven (11) Drawer cabinet shall be used o Compartment with drawer slide (for sockets and adaptors); fold down doors used as worktables. Bottom area of this compartment is for Sledgehammer, pry bars and Digging bars.

o Access to tools and drawers shall not be hindered by worktables.

o Compartment with large doors (for air tools)

Passenger’s (curb) side from front to rear:

o Generator compartment and DC components modified and reinforced as required to hold generator and provide slide out access for service is optional. Generator shall be easily accessible for service.

o Compartment with drawer slide with fold down doors that can be used as worktables.

o Air Hose Retractable Reel, capability to be accessible from exterior of vehicle.

o Electrical cord retractable reel, an electrical outlet, and AC components.

o All tools shall be secured within tool truck compartments to prevent shifting during vehicle movement yet still allowing for easy removal.

All exterior compartment shall be made of a rust proof material.

3.3.2 Service Body Mounting

The body longitudinal substructure shall be bolted to the chassis utilizing full floating rubber body isolator mounts. Stainless steel compression washers or strips shall be used under all bolts and nuts to prevent crushing of the structure.

The number of body isolation mounts utilized on each frame rail shall be as specified in the vehicle manufacturer’s body builder handbook to handle weight of completed body with equipment installed.

OEM Service Body mounting instructions shall be adhered to.

3.3.3 Tools

See Appendix #2 for the list of tools to be provided. The tools shall be industrial grade and provided with a lifetime warranty that Costa Rican Authorities may exercise with the Original Equipment Manufacturer (OEM) to obtain replacements and/or service.

3.3.4 Fuel System

Fuel tank filler neck cap shall be secured to the filler neck to prevent against loss.

A permanently attached (with screws or rivets) embossed plate shall be affixed next to the tank filler opening in the body, identifying the type of fuel/fluid (Diesel or DEF). The fuel tank door shall be lockable to prevent siphoning.

The fuel system for the vehicle engine and generator shall conform to all Federal Motor Vehicle Safety Standards (FMVSS) 301 (49 CFR 571.301) requirements, and utilize the chassis manufacturer’s furnished auxiliary connections according to the manufacturer’s technical requirements for connection of generator fuel lines.

The total fuel capacity of the vehicle shall be 40 gallons or better. If additional fuel tank is required to meet the 40-gallon capacity requirement; it shall be installed to feed the vehicle main fuel tank. The fuel feed for the generator shall be installed so that it does not empty the vehicle’s main fuel tank if below ¼ (one quarter) tank.

3.3.5 Payload Capacity

The Payload Weight shall not exceed the Payload Capacity of the truck. This is the total weight that a vehicle carries. This includes the weight of the occupants, cargo, options and other equipment. Curb weight is the vehicle weight without the driver, passengers or cargo. This weight includes all fluid levels topped off including a full tank of fuel and other items of standard equipment on Vehicle as completed, in road travel configuration (full curb weight, including full fuel tank, six passengers at 220 lbs. each, all mounted equipment and miscellaneous equipment), shall be below the Gross Axle Weight Rating (GAWR) with each axle below the Gross Vehicle Weight Rating (GVWR) overall. Vehicle loading shall be split approximately 35% front and 65% rear in road travel configuration. Weight variance between left and right side shall be no more than 5%. The vertical and horizontal unit Centers of Gravity (CG’s) shall be within the envelope recommended by the incomplete vehicle documents supplied by the vehicle manufacturer.

3.3.6 Wheel and Tires

All tires shall be rated as all-season steel belted sidewall with a footprint wide enough to handle soft soil floatation. A valve extension hose for rear inner dual wheels shall be provided. A secured full size spare tire and wheel assembly shall be provided. Secure stowage for the spare tire assembly and tools for removal and installation of tire(s) shall be provided.

3.3.7 Rear Bumper

The rear of the vehicle shall be equipped with a full-width bumper, secured to the vehicle chassis frame. The rear bumper shall be adequate to support a test weight of 300lbs without flexing. The end of the bumper shall not extend past the width of the body, nor extend below the body with two (2) retractable steps one on each side of the bumper. An additional middle step may be required if the service body floor is at the higher heights allowed in section 3.3.1.

3.4 Emergency Lighting/Siren

The vehicle shall be equipped with a Whelen 400 Series Single Level Linear- Super LED light (Blue) or equivalent for a total of 8 lights, lighting shall be visible from 360 degrees; mounted on the roof top of vehicle, front grill, and rear body panel and sides; power-supplied control-mounted unit with a status display in the driver compartment; installed in full compliance with manufacturer’s guidelines.

The siren shall include at a minimum two tones, the wail and yelp, plus PA system, (such as the Whelen PA series or equivalent). The siren may be integrated with the lighting or separate.

3.4.1 Security System

The vehicle shall be equipped with one complete alarm system for all the service body doors with two remote control devices. The vehicle chassis shall have a security system as supplied by the manufacturer.

3.4.2 Back- up Alarm and Back-up Camera

The tool truck shall be equipped with an audible alarm when vehicle is in reverse.

The tool truck shall include a back-up camera.

3.5 Miscellaneous Safety Items

3.5.1 First Aid Kit

An OSHA approved first aid kit similar to Large Trauma First Aid Kit - AA409, shall be provided and mounted in the service body.

3.5.2 Fire Extinguishers

Two (2) ABC fire extinguishers, one 2.5 lbs for vehicle cabin and one 5 lbs shall be installed in the service body.

The location of the extinguishers shall be identified by a red/white label placed on the outer panel or door for each extinguisher.

3.6 Electrical System (110/120 VAC and 12 VDC)

The Government shall approve the wiring diagrams for the 110/120 VAC and 12 VDC systems. Chassis OEM furnished electrical system interfaces shall be utilized to the maximum extent possible. The output from the generator shall feed the power requirements for lighting, air compressor, all power tools, and AC outlet requirements.

All wire routing shall allow for potential configuration changes and additions subsequent to replacement of the vehicle in-service. (i.e., wire shall be accessible, not hidden inaccessible body cavities.)

Wire shall be stranded copper, minimum AWG 14 gauge for 15 amp circuits, 12-gauge for 20 amp circuits. All wiring shall be stranded copper with SXL insulation.

Cable splices shall only be permitted in junction boxes.

All wiring shall be supported with rubber insulated cable clamps at a minimum interval of 18 inches.

Wire termination at the breaker box or any junction block shall have a minimum of 6 inches of extra wire to provide for any future terminal or splice replacements.

All wiring shall be in accordance with the applicable requirements of SAE J1292.

All in-line wiring connections shall utilize locking lip seal type connectors.

Wiring shall be routed in a flexible, high temperature (350- 400 Fahrenheit) loom or conduit.

All wiring run in exposed areas susceptible to contact with personnel shall be run in 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 cannot be abraded or damaged by any part of the chassis, engine, or body.

Grommet 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 crimpled to assure that they grip both the wire insulation as well as the conductor. Terminal attachment shall comply with SAE J163, and the terminations themselves must comply with SAE J561 (ring and spade types), SAE J858a (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.

Circuit breakers, fuses, or fusible links shall be located such that no disassembly or relocation of other components shall be necessary for replacement or maintenance.

All switches, relays, connectors, and all other electrical components shall be rated for a minimum of 125% of the maximum current for which the circuit is protected. Environment sealed switches shall control 12- volt lighting systems.

Wire and circuit breaker size shall be as follows:

Minimum Wire Size Maximum Circuit Breaker

#18 AWG

#16 AWG

#14 AWG

#12 AWG

#10 AWG

#8 AWG

5 AMP Max 10 AMP Max 15 AMP Max 20 AMP Max 30 AMP Max 50 AMP Max

Wiring terminal used in all body 12 V. wiring shall grip the wire insulation as well the conductor. Flexible loom or conduit shall be used in routing all 12 V. wiring.

3.6.1 110/120-Voltage AC (VAC) System

The 110/120 VAC electrical system shall include one (1) generator that is adequately powered to meet or exceed the electrical requirements. The 110/120 VAC system shall include a 110VAC to 12VDC converter to supply 12VDC power for all 12VDC body systems and lights and charge the vehicle and system battery. The 110 VAC systems shall run the air compressor system, outside scene lights and interior and exterior outlets as required. All outlets interior and exterior shall be equipped with a ground fault circuit.

3.6.1.1 110/120 VAC Exterior Outlets

Two (2) exterior duplex, 110/120 VAC outlets, Certification of Electromechanical Equipment (CEE) 7/7 (CEE 7 standards sheet VII) shall be furnished, one on each side, on one of the outside equipment compartments. Exterior outlets shall meet minimal US specification grade, flush mounted in exterior rated enclosures rated for wet locations when closed and damp locations when open or closed, with springs loaded covers.

3.6.1.2 110/120 VAC Interior Outlets

A minimum of four (4) duplex VAC, specification-grade interior outlets shall be provided, two each along the walls of the service body. All outlets shall be duplex 20-amp, 2-pole, three wire, and grounding receptacles. Final location shall be reviewed and approved by the Government at the vehicle design review.

3.6.1.3 110/120 VAC Flood Lighting System

The vehicle shall be equipped with LED lights, four (4) fixed and two (2) moveable scene/stadium lights (six total). Service body scene lights shall be 3000 lumens or better. Flood lamps, with an extendable inspection (pole) at the rear driver and passenger-side corners of the service body. Each shall be 110/120VAC, 20K lumens. This will provide high-intensity scene lighting around the vehicle. Lights shall be on an extendible and rotatable mast to allow extension above the height of the truck roof for illumination of the scene. The pole lights shall not interfere with any of the vehicle operation or emergency lights when they are stowed. Mast shall have folding tripod base and be removable for hand carry to required locations. Padlocks, combination type, locking each mast to the tower mounting bracket shall be furnished. Lamp heads shall be aluminum, weatherproof tempered glass lenses and shock resistant fixtures.

3.6.2 12VDC Dome Lamps

The vehicle shall be equipped with a minimum of four (4) 12-volt overhead LED interior lights within the service body. The lights shall be spaced equally along the center line of the service body ceiling. A motion detector sensor/switch shall be installed that will automatically turn lights on when someone enters the service body doors. A 2-minute timer shall be utilized to turn all dome lights off.

An additional three (3) position switch shall be installed on the interior wall near the side entrance door to control all the interior dome lights.

3.6.3 12VDC Vehicle Body Lighting

All stop, turn, tail, back-up, clearance, hazard, and marker lights shall be grommet-mounted Truck- Lite or equivalent, LED light fixtures for body-mounted lights. Body harness wiring shall utilize only molded or machine made splices.

No tapes, wires nuts, or twisted wire connection method shall be used. All lighting devices and reflectors and their location on the vehicle shall conform to FMVSS 49 CFR 393.9, 393.11, and 571.108.

3.7 Generator

The Contractor shall provide one (1) adequately powered diesel generator (which meets or exceeds electrical requirements) to provide 110/220 VAC power. The generator shall be mounted on the passenger’s side of the body behind the cab forward of the rear wheels in an exterior compartment. The generator control panel shall be located with the generator and a start switch shall be mounted so the generator does not need to be extended on the slide to start. The generator controls shall be generator OEM designed to interface with the generator, and contain (at a minimum) an hour meter, voltmeter (AC/DC), and an engine remote start/stop switch. The generator shall be capable (via a switch) of being started with either chassis or deep cycle batteries. Water tight, flexible conduit shall be used at the generator to allow the generator to be fueled from the chassis’ fuel tank through a dedicated fuel pick-up supplied by the vehicle manufacturer, and include check valves to prevent fuel drain-back, and set up to prevent completely draining the main fuel tank.

The generator exhaust shall be routed to the body perimeter. The exhaust piping shall be stainless steel and shall be designed and installed according to the generator’s manufacturer’s installation requirements. The generator shall be tested to demonstrate its capability to deliver its full rated load at its regulated voltage and frequency.

The generator shall be noise suppressed and shall not exceed noise levels of 75dB (decibels) at five feet from generator. The installed generator running at rated full load shall not exceed the sound level requirements of the vehicle stated above.

The generator shall be capable of providing sufficient power to simultaneously operate the air compressor, service battery charger, pole inspection lights mounted on the rear of the truck service body, plasma cutter, and the several utility outlets located around the truck. A mounted retractable 100-ft extension cord shall be included and mounted within a compartment to guard against weather. The power cord on this reel shall be able to support the use of the plasma cutter.

3.7.1 Generator Compartment

The compartment shall be located forward of the rear wheels on the passenger side of the vehicle to allow for easy access. Exhaust air from the cooling system shall be ducted directly out of the compartment to a location where recirculation to the intake area is minimized. Design of the genset compartment and installation of the genset shall adhere strictly to the requirements of the genset manufacturer. The compartment shall be sized and ventilated as necessary to provide the genset manufacturer’s recommended engine and generator cooling air circulation. Mounting of the generator tray shall be from the chassis frame rails. The compartment and door shall be dimensioned to provide adequate access to the genset compartment for servicing and ventilation. One paddle latch lockable mounted flush with the exterior surface shall be provided to secure the generator compartment. The lock shall be keyed alike with those for other exterior doors. The doors shall be hinged from the side with stainless steel piano hinges. A stainless steel Government approved retainer shall be furnished to hold the door open and prevent it from closing. The service body shall be modified by the Contractor as required.

3.8 Deep Cycle Batteries

Two (2) 12V deep-cycle batteries with a minimum 20 hour rating of 215 amp-hr and/or equivalent reserve capacity shall be furnished. These shall be wired in parallel to provide power for all body interior and communications equipment.

Batteries shall be installed underbody in a weather resistant compartment, on a slide out tray. Charging shall be by vehicle alternator and by battery charger. All connections shall be made at the load end of the battery cables. These batteries shall be capable of being switched to start either the vehicle or generator.

3.8.1 Battery Isolator

The deep cycle auxiliary load batteries and the vehicle high cycle batteries shall be isolated from each other with a battery isolator system. The vehicle alternator system and the 110/120VAC to DC converter shall be capable of charging both sets of batteries through the isolator(s). The isolator system shall be approved by and installed in conformance to both the vehicle manufacturer and the isolator manufacturer.

3.8.1.1 Battery Charger

The battery conditioner shall maintain all batteries in fully charged state without gassing the electrolyte (over charging). The conditioner shall receive power whenever the 110/120VAC circuits are energized, whether through the generator or shore power.

3.8.1.2 Shore Power

Shore Power connection shall be installed to include a 50-foot power cord with 30 amp twist lock type connector to power the service body and tools.

3.8.2 12 Volt Systems

12V systems shall consist of two distinct sections. One section shall power the OEM chassis components and equipment, including engine starting, using high-cycle design batteries. The second section shall utilize deep cycle batteries (service battery) for starting the generator, powering 12V equipment, and accessories, including communications gear, body interior lighting, etc. Both battery banks shall be charged by the vehicle engine alternator as well as 110/120VAC generator power when energized. The service battery does not normally start the vehicle engine but shall have a manual switch to connect the service battery to start the vehicle engine.

3.9 Air Compressor System

The air compressor system shall be capable of providing 11 cfm (continuously) or better to adequately power two applicable tools simultaneously from the attached tool list.

The output of the compressor shall be plumbed to the mounted retractable air hose reel as shown in attachment #1 and two auxiliary outlets connections shall be mounted; one next to the air compressor and one inside the compartment next to the air hose.

The air compressor shall be mounted in such a way as to allow for easy maintenance.

Shock mounting system to be used.

Condensate air water separator shall be installed.

3.9.1 Air Compressor Service Disconnect

There shall be a service disconnect mounted next to the air compressor to disconnect the 110/220 VAC power from the air compressor. Service panel for other electrical circuits can be co-located.

3.10 Trailer Towing Package

A trailer towing package consisting of a Tri-ball Hitch Ball Mount (with 1 ⅞ -2 inch and 2 5/16 inch ball), a pintle, a safety chain attachment device, a light/brake receptacle, and associated reinforcements shall be provided. Wiring shall be installed on the rear of the vehicle. The receiver shall be installed to the chassis frame or reinforced bumper, with reinforcements to transfer loads directly to the chassis frame rails. Two (2) trailer safety chain attachment devices, one adjacent to each side of the receiver, shall be provided. Each attachment device shall provide a minimum rated strength of 12,000 lbs. and 2,400 lbs. minimum vertical weight rating; the installed system shall be rated no less than the rating of the hitch. The lighting receptacle, shall be mounted in a readily accessible location near the hitch. The receiver hitch shall accommodate a ball insert with 2 inch x 2 inch shank.

3.10.1 Trailer Electrical Connector

A round water resistant 7-pin trailer wiring connector socket shall be furnished on the rear of the vehicle for connecting the trailer electrical cables as provided by the chassis manufacturer. The hitch height shall be set 17 inches from ground level.

The trailer socket shall be connected to the OEM installed trailer wiring harness.

4.0 MISCELLANEOUS REQUIREMENTS

4.1 Markings, Data Plates

A permanent aluminum or plastic plate, indicating the name of the manufacturer;

vehicle type; year and model number; warranty expiration date (month and year);

manufacturer’s vehicle identification numbers and vehicle dimensions, including overall height, width, length and GVW, shall be permanently affixed to the vehicle in one of the following locations: inside the glove box door or on the driver’s side door post. Actual location shall be subject to the approval of the Government.

Data shall be permanently and legibly inscribed on the plate.

The Contractor shall provide vehicle identification information and CR Contraband Enforcement Team on the vehicle. Final design and placement of all data plates and decals shall be in accordance with the Costa Rican Grupo de Interdiccion de Contrabando markings are appropriately placed on each vehicle in accordance with CR LE Authorities branding guidelines.

4.1.1 Paint, Finish, and Color

The completed conversion package shall be primed and painted. All surfaces shall be prepared and painted in the following manner: All paint applications shall conform to the paint manufacturer’s requirements and recommendations.

Paint surfaces shall be able to withstand being cleaned with solvent, chemical, or mechanical methods in accordance with the paint manufacturer’s recommendations.

A rust inhibitive primer shall be applied with a minimum dry film thickness of 1.5 mils.

A two part polyurethane topcoat shall be applied with a minimum dry thickness of 2.0 mil.

Paint Schematic, PT-1 Single Color: White

4.1.2 Interior Information Decals

Unless otherwise specified, interior markings and decals shall be vinyl silk-screen process with a pressure sensitive adhesive backing.

Generator Instructions: “Safety Checks” and “Start-up Procedures” for the generator shall be permanently posted in a Government approved location.

A Vehicle Backing Warning Decal, containing the legend “Look before Backing” in 1 inch lettering, shall be affixed to the dashboard in a Government approved location.

Clearance Warning Decal: The minimum height clearance of the body shall be measured and indicated on a decal located in the view of the driver.

4.2 Operators, Servicing, and Parts Manuals

The Contractor shall provide one chassis OEM operator’s manual and service manual for each tool truck and shall include operating manuals for all installed equipment, systems, and components, in accordance with. The literature shall include descriptions of all systems, and component items furnished on the vehicle including, but not limited to, the following: Operator’s manual, service manual, parts catalog, lubrication charts, hydraulic system, generator system, converter, breaker panel, lighting components, A/C system, heater system, and any other component furnished. The service manuals shall include separate electrical as-built wiring diagrams.

4.3 Drawings and Weight Calculations

The Contractor shall provide all conceptual and weight estimation drawings as required in previous paragraphs (i.e., paragraphs 3.3.5) and the verification section with the proposal. Final weight tickets are required.

4.4 Workmanship

Vehicles shall be free from defects.

All bodies, systems, equipment and interfaces with the chassis shall be assembled in accordance with the OEM’s Service Body Builders Book.

Whenever dissimilar metals are used they shall be insulated against corrosive action.

All components shall be new. Component parts and units shall be manufactured to definite standard dimensions with proper fits, clearances and uniformity. Welded, bolted and riveted construction utilized shall be in accordance with industry best practices. General appearance of the vehicle shall not show any evidence of poor workmanship.

The following are examples of poor workmanship that will be cause for rejection (this list is by no means all-inclusive and is provided merely as examples):

o Rough, sharp or unfinished edges, burrs, seams, corners, and joints.

o Non-uniform panels. Edges that are not radiuses, beveled, etc.

o Paint runs, sags, orange peel, “fish eyes”, etc.., and any other imperfection or lack of complete coverage of paints or coatings.

o Body panels or components that are uneven, unsealed, or contain cracks, dents or have voids.

o Misalignment of body fasteners, glass, viewing panels, light housings, other items with large or uneven gaps, spacing etc. such as door, body panels and hinged panels.

o Improperly fabricated and routed wiring or harnesses, and electrical connections.

o Improperly supported or secured hoses, wiring harnesses, mechanical controls etc., including interference with other components.

o Interference of chassis components, body parts, doors, etc.

o Leaks of any gas, vacuum, or fluid lines (air conditioning, coolant, oil, etc.).

o Noise, panel vibrations, etc.

o Inappropriate or incorrect use of hardware, fasteners, components, or methods of construction.

o Incomplete or improper welding, riveting, or bolting.

o Lack of uniformity and symmetry where applicable.

o Loose, vibrating, abrading body parts, components, sub-assemblies, hoses, wiring harnesses or trim.

o Improper body design or interface with the chassis that could cause injury during normal use or maintenance, and which fail to provide access to perform routine or mandatory repairs or maintenance on vehicle electrical and mechanical systems. In addition, the improper combination of options which by their combination and installation are inherently incompatible with regard to function or safety.

o Visual deformities and equipment malfunctions.

o Unsealed accessories or other body components, gaskets, etc.

o Visual deformities and equipment malfunctions.

o Unsealed appurtenances or other body component, gaskets, etc.

o In addition, any deviation from specification requirements or any other item, whether or not stipulated herein, that affects form, fit, function, finish, durability, reliability, safety, performance or appearance shall be cause for rejection.

o Caulking where service body meets shall be uniform and neat.

4.5 Externally Threaded Fasteners

Externally threaded inch-series steel bolts, screws, seams (screw and washer assemblies), studs, and U-bolt in sizes up to and including 1 ½ inches, shall be a minimum of SAE Grade 5 and meet the specifications of the most current revision of SAE J429-Mechanical and Material Requirements for Externally Threaded Fasteners. Metric externally threaded fasteners, if specified as required, shall meet the specifications of the most current revision of SAE J1199- Mechanical and Material Requirements for Metric Externally Threaded Fasteners. Metric fasteners shall be a minimum of Class 8.8 (size M17-M36) or Class 9.8 (size M1.6-m16). In addition, these fasteners shall be furnished in accordance with ASME/ANSI B18.18 1M-1987- Inspection and Quality Assurance for General Purpose Fasteners.

4.6 Government Acceptance Testing

4.6.1 Generator Load Test

The Contractor shall provide documentation from the generator supplier at the Verification Design Review that the generator meets all requirements under all specified voltage, frequency, and power factor ratings with the Contractor.

The generator shall be tested to demonstrate its capability to deliver its full rated load at its regulated voltage. The Contractor shall provide the facility and load bank to perform a 60-minute full load test (resistive load test) of the generator on the pilot vehicle.

The generator shall be tested to show that it meets other requirements: at 120 VAC, 50Hz, voltage regulation of +/-2% @ no load to full load/ full load to no load cycle shall be performed during the test and time to stabilize voltage demonstrated during the test. While at full load, a sound level test shall be conducted.

4.6.2 Pre-Service Inspection

The Contractor shall perform a pre-service inspection of the production vehicles based, at a minimum, on Technology and Maintenance Council (TMC) RP 803- Pre-Service Vehicle Inspection. All items listed in RP 803 shall be inspected and verified as satisfactory with all adjustments noted and verifications that all needed repairs have been made. A copy of the RP 803 shall be made available to the Government inspector and shall be kept with the vehicle as part of the shipping documentation.

4.6.3 Road Test

All production vehicles shall be road tested before delivery. The road test shall be of sufficient duration to bring the engine and transmission to their normal operating temperatures at a minimum distance of 10 miles. The road test shall meet all requirements in sections F (road test) and section G (after road test) of TMC RP 803 Pre-Service Vehicle Inspection are verified as acceptable. All adjustments shall be noted and verified that any and all deficiencies have been corrected. A copy of the completed inspection report for each tool truck shall be made available to the Government inspector, and shall be included with the shipping documentation.

4.6.4 Water Spray Test

Each side, front, rear, and top, of the vehicle shall be subjected to water spray test in accordance with MIL-STD-810G, part two, Method 506.4 Procedure I- Blowing Rain. The test procedure shall include the following:

Rainfall rate: 4.5 to 5.5 in./hour

Droplet size: 0.5 to 4.5mm (.02 to .18 in.) in diameter

Wind velocity: 70 mph

Any evidence of water penetration into the vehicle body or exterior compartments shall be reason for rejection.

Alternatively, the Contractor’s standard water spray test may be used in lieu of the MIL-STD-810G if the…