ATTACHMENT 2- Crew Carrier Body Specifications June 2023.pdf

Ten Person Crew Carrier Apparatus Body Only Specification

Issue Date: June 2023

Supersedes: January 2022

Apparatus Body Only Specification Ten Person Crew Carrier – Supersedes January 2022

TABLE OF CONTENTS

TABLE OF CONTENTS

RECORD OF REVISIONS

1 — GENERAL

1.1 Compliance with NFPA 1906

1.2 In-Service Weight Requirements

1.3 Tilt Test

1.4 Departure Angle

1.5 Driver Controlled Rear Locking Differential

1.6 Structural Integrity

1.7 Federal Motor Vehicle Safety Standards

1.8 Brand Name or Equivalent Products

1.9 Government-Furnished Chassis (Disregard if ordered turnkey)

2 — CHASSIS ELECTRICAL REQUIREMENTS

2.1 Chassis Electrical Additional Equipment and Modifications

2.2 Battery Master Switch

2.3 Jump Start Stud

2.4 Back Up Alarm

2.5 Map Light

2.6 Ground Lighting

2.7 Antennas

2.8 USFS Installed Radio Pre-Wire

2.9 Auxiliary Lighting

2.10 Rear View Backup Camera System

2.11 Tire Pressure Monitoring System (TPMS)

3 — TRAFFIC WARNING SYSTEMS

3.1 Traffic Warning Systems

3.2 Electronic Siren

3.3 Speaker

3.4 Forward Upper Zone A/B/D Lightbar

3.5 Aft Upper Zone B/D Warning Lights

3.6 Upper Zone C Warning Lights

3.7 Lower Zone A Warning Lights

3.8 Forward Lower Zone B/D Warning Lights

3.9 Lower Zone C Warning Lights

3.10 Air Horn

3.11 Headlight Flasher

4 — CHASSIS ADDITIONS AND MODIFICATIONS

4.1 Additional Equipment Installation

4.2 Apparatus Fluid Types and Quantities

4.3 Seating Capacity

4.4 Seat Belt Warning

4.5 Vehicle Height Warning

4.6 Final Stage Manufacturer Vehicle Certification

4.7 Noise Hazard Warning

4.8 Air Filter Ember Protection Screen Warning

4.9 Cab Console

4.10 Center Console Aft Storage

4.11 Front Tow Hooks

4.12 Tow Eyes

4.13 Front Fenders, Rubber

4.14 Mud Flaps

4.15 Exhaust System

4.16 Heat Protection

4.17 Air Line, Fuel Hose, Electrical Harness and Connector Protection

4.18 Cabin Air Ember Guard

4.19 Auxiliary Air Outlet

4.20 Under Cab Storage Compartment

5 — CREW CARRIER BODY DESCRIPTION

5.1 Body Design

5.2 Structural Integrity

5.3 Body Construction

5.4 Body Sub-Frame

5.5 Body Materials

5.6 Body Mounting

5.7 Rear Step/Bumper

5.8 Rear Skid Plate

5.9 Body Protection Panels

5.10 Body Dimensions

5.11 Compartmentation

5.12 Driver's Side Compartments

5.13 Passenger's Side Compartments

5.14 Compartment Doors – Steel Overlap Type

5.15 Door Latches and Hardware

5.16 Door Hold Open Devices

5.17 Compartment Floor Mats

5.18 Adjustable Shelf Channels

5.19 Compartment Shelves

5.20 Crew Compartment Interior

5.21 Crew Compartment Windows

5.22 Crew Compartment Roof Vent and Escape Hatch

5.23 Camper Boot

5.24 Crew Compartment Heating and Air Conditioning Unit

5.25 Air Conditioning Condenser Guard

5.26 Crew Compartment Seating

5.27 Seatbelts

5.28 Crew Compartment Overhead Storage

5.29 Crew Compartment Lower (Personal) Storage

5.30 Crew Compartment Rear Storage

5.31 Crew Compartment Lighting

5.32 Crew Compartment Rear Access Door

5.33 Grab Handles

5.34 Spare Tire Storage

5.35 Drip Rails

5.36 Wheel Wells

5.37 Wheel Chock Mounting Brackets

6 — BODY ELECTRICAL REQUIREMENTS

6.1 General Requirements

6.2 Electrical Equipment

6.3 Rear DOT Lighting

6.4 Tail Lights, Brake Lights

6.5 Turn Signal Lights

6.6 Back Up Lights

6.7 License Plate Bracket and Light

6.8 Cluster/Clearance Lights and Reflectors

6.9 Rear Directional Light Bar

6.10 Scene Lights

6.11 Compartment Lights

6.12 Power Inverter

7 — ELECTRICAL SYSTEM PERFORMANCE TEST, LOW-VOLTAGE

7.1 Test Required

7.2 Test Sequence

7.3 Reserve Capacity Test

7.4 Alternator Performance Test At Idle

7.5 Alternator Performance Test at Full Load

7.6 Low Voltage Alarm Test

7.7 Documentation

8 — APPARATUS FINISH

8.1 Body Finish Procedure

8.2 Crew Carrier Body Color

8.3 Chassis Finish

8.4 Striping

8.5 Cab and Body Lettering and Striping

8.6 Truck Identification Plate

8.7 Door Decal (Shield and Vehicle Numbers)

9 — BODY ELECTRICAL REQUIREMENTS

9.1 Equipment Provided

9.2 Manuals and Drawings

9.3 Road Kit

9.4 Wheel Chocks

10 — WARRANTY PROVISIONS

10.1 Ten Year Apparatus Warranty

Record of Revisions

Date Revision summary

June 2011 • Initial Release August 2011 • Revision

February 2012 • Revision January 2015 • Added Table of Contents

• Added Record of Revisions since February 2012

• Revised chassis system voltage drop for accessories to turn off

• Added auxiliary lighting, mounted in bumper cutout

• Revised cab console layout

• Added requirement that exhaust system shall also be clear of the spare tire

• Clarified requirements of roof seam welding

• Added requirement for protection of wiring, etc. close to cable loop

(mounting)

• Added means to secure rear step when stowed

• Revised required size of body protection panels

• Added segregated battery compartments to driver's side

• Deleted ventilating louvers from driver's side horizontal compartment

• Added ventilating louvers to driver's side compartment aft of rear wheels

• Revised compartment shelves; 20 shelves total

• Added that Avex type rivets may be used in crew compartment interior

• Deleted bulkhead padding

• Revised crew compartment lighting brand

• Revised crew compartment reading lights

• Added requirement for provisions regarding spare tire storage

• Changed size (diameter) of clearance lights

• Changed from self-adhesive reflectors to riveted reflectors

• Added requirement for rear directional control head

• Changed letter size (height) of unit and equipment designators

• Deleted word “Hotshot” in reference to crew name

• Added size (height) of Crew Name on side of body

• Added requirement for Crew logo on rear crew compartment access door

Date Revision summary

• Added the emergency exit hatch shall be labeled

• Revised apparatus warranty to ten years

February 2016 • Updated Format

• Updated Govt. Provided Chassis Options

• Modified compartment design to include placement of DEF tank

• Added Hydraulic Jack and Lug Wrench Specification

January 2017 • Changed lighting specifications

• Added USB charging outlets to cab console

• Added USB charging outlet to each seating position

• Added crew compartment door gas spring device

• Updated cab & body lettering/striping

• Added under cab storage (if space allows)

February 2018 • Added rearview backup camera system

• Added tire pressure monitoring system

• Amended brand name or equivalent products

• Amended traffic warning system wording

• Amended crew compartment seating

January 2022 • Amended brand name or equivalent products

• Added requirement for Forest Service door decal

June 2023 • Formatting

• Amended Tire Pressure Monitoring System (TPMS)

• Amended Air Conditioning

[Future revisions] • This space is reserved for future revisions.

1 — General

1.1 Compliance with NFPA 1906

1.1.1 The apparatus described in this specification shall be compliant with the requirements of NFPA 1906, latest edition, except where noted. Any deviations from NFPA 1906 shall be noted in this specification or shall be approved in writing by the Government.

1.2 In-Service Weight Requirements

1.2.1 The in-service weight shall meet DOT gross axle and vehicle weight requirements; shall meet Forest Service Handbook (FSH) 7109.19 vehicle loading requirements using a rough road factor of 0.90; and shall not exceed 20,000 pounds on the rear axle when loaded as follows:

• With 250 pounds per seat, and

• With 1600 pounds allowance for tools, equipment and supplies evenly distributed in the storage compartments.

1.3 Tilt Test

1.3.1 The apparatus shall be tested at the estimated in-service weight in accordance with NFPA 1906.

1.4 Departure Angle

1.4.1 The departure angle shall be 20° minimum when loaded as specified.

1.5 Driver Controlled Rear Locking Differential

1.5.1 When the apparatus is driven over 15 miles per hour the driver-controlled rear locking differential shall automatically disengage and shall not automatically re-engage when driven below 15 miles per hour.

1.6 Structural Integrity

1.6.1 This specification requires testing and certification of the structural integrity of the body by an independent third-party laboratory or test facility. Computer simulations or analyses are not acceptable. The requirements for structural integrity testing are included in the chapter titled "Crew Carrier Body Description."

1.7 Federal Motor Vehicle Safety Standards

1.7.1 Compliance with all applicable Federal Motor Vehicle Safety Standards (FMVSS) is required. Certificates of conformance shall be provided to the Government for the following standards:

• FMVSS 207 — Seating Systems

• FMVSS 209 — Seat Belt Assemblies

• FMVSS 210 — Seat Belt Assembly Anchorages

• FMVSS 302 — Flammability of Interior Materials

1.8 Brand Name or Equivalent Products

1.8.1 Products equivalent to the brand name components specified herein may be approved by the Government. Equivalent products shall not be used unless approved in writing by the Government prior to contract award and documented in the resultant contract. After the contract award, approvals for equivalent products may be considered, and if approved, shall be documented in writing by the Government.

1.9 Government-Furnished Chassis (Disregard if ordered turnkey)

1.9.1 The government furnished chassis will be equipped as follows:

• Wheelbase: 165 inches

• Cab-to-Axle Length: 98 inches

• Power train: 300 horsepower and 860 foot-pounds torque minimum; Allison 3500

EVS automatic transmission

• Front Axle and suspension: 10,000-pound gross axle weight rating

• Rear Axle and suspension: 21,000-pound gross axle weight rating minimum, Hendrickson™ PRIMAAX® EX 23,000 pound suspension

1.9.2 An optional chassis may be furnished by the government as follows:

• Wheelbase: 165 inches

• Cab-to-Axle Length: 98 inches

• Power train: 330 horsepower and 1000 foot-pounds torque minimum; Allison 3500

EVS automatic transmission

• Front Axle and suspension: 10,000-pound gross axle weight rating

• Rear Axle and suspension: 23,000-pound gross axle weight minimum, Hendrickson™ PRIMAAX® EX 23,000 pound suspension

2 — Chassis Electrical Requirements

2.1 Chassis Electrical Additional Equipment and Modifications

2.1.1 The crew carrier chassis shall be equipped with a heavy-duty 12-volt direct current (VDC) negative ground electrical system. The electrical system shall include all parts, components, switches, relays, wiring, and other devices required to assure complete, consistent and proper operation of the completed apparatus.

2.1.2 All lights are required to comply with Federal Government Codes for vehicles of this size and design shall be provided and installed. These lights shall include headlamps and front turn signals with hazard switch, cab marker and clearance lights, back up lights, stop-turn-tail and license plate lights.

2.1.3 All switches for the warning lights, auxiliary lights, and other electrical equipment shall be mounted on a separate switch panel located on the center console in the cab interior. The switches shall be functionally laid out, properly identified, and shall be located within easy reach of both the driver and the officer. The warning light system shall have a “master” switch, which shall allow for the pre-selection of all warning lights. All switches shall be of a heavy duty design.

2.1.4 The following accessories shall turn off via an LVD (low voltage disconnect) switch when the chassis system voltage drops to 11.8 volts direct current:

• Power inverter

• Ground lights

• Scene lights

• Crew compartment lights

• Crew compartment heating and air conditioning unit

• 12-volt chargers

• Rear directional light bar

• Map light

2.1.5 The emergency lighting shall turn off via an LVD (low voltage disconnect) switch when the chassis system voltage drops to 11.8 volts direct current.

2.1.6 The following additional electrical equipment shall be installed on, and modifications performed to, the specified cab and chassis by the apparatus builder:

2.2 Battery Master Switch

2.2.1 One battery selector switch shall be provided in the cab. The switch shall be rated for 310 amps continuous duty and 500 amps intermittent duty. The switch shall be located on the floorboard to the left side of the driver's seat and placed as far aft as possible to protect accidental actuation and labeled ON/OFF. The exposed terminals shall be protected from damage and inadvertent contact. One switch that meets these requirements is the Cole Hersee™ brand #75920 ON/OFF, 400A Continuous/1000A Intermittent.

2.2.2 Power to the chassis electronic control module shall be maintained when the switch is in the OFF position.

2.3 Jump Start Stud

2.3.1 The OEM auxiliary positive battery post shall be mounted on the driver's side, near the cab door and front of the apparatus body. The post shall be used to jump start the vehicle and be connected to the vehicle's starting batteries

2.4 Back Up Alarm

2.4.1 One solid state back up alarm shall be provided at the rear of the apparatus protected from impact and debris. The back-up alarm shall be wired to the reverse circuit of the transmission, and shall provide an audible alarm to the rear of the apparatus when reverse gear is selected. The alarm shall have a volume of 87 to 112 decibels while in operation.

2.5 Map Light

2.5.1 One flexible goose neck, L.E.D. map light shall be provided on the cab center console. One switch for the map light shall be located on the center console. One switch shall also be located on the light and shall include a three-way switch for white light and red light.

2.6 Ground Lighting

2.6.1 Four 2-inch clear L.E.D. lights shall be provided under the chassis steps, ground-facing, two on each side. The lights shall be angled to illuminate the area under the chassis cab steps.

Lights shall be wired to the cab door switch and a switch in the cab and shall turn on automatically when a cab door is open.

2.6.2 One 4-inch L.E.D. light shall be provided near the rear step area under the bumper. The light shall be wired to the crew compartment rear access door and a switch in the cab and shall turn on automatically when the rear access door is open.

2.6.3 The ground light switch on the cab console shall enable the ground lighting to be either turned on with the door switches (“ON” position) or override the door switches and turn off all ground lighting (“OFF” position).

2.7 Antennas

2.7.1 Two antenna MNO Type bases with rain caps installed shall be supplied and mounted on the cab roof as specified. The antenna cables shall be routed to the cab interior, terminating at location of radio mounting bracket.

2.8 USFS Installed Radio Pre-Wire

2.8.1 The chassis cab interior shall be wired with power, ground, ignition switched power, and radio pre-broadcast wires to the siren or PA, and labeled to simplify USFS radio installation.

2.9 Auxiliary Lighting

2.9.1 A pair of white L.E.D. auxiliary lights shall be installed in the center bumper cutout on either side of the license plate location. They shall be capable of being adjusted for both elevation and azimuth. The distance between the two lights shall be maximized. Each light shall produce a minimum of 3000 lumens, and be equipped with a diffused lens capable of projecting light with flood pattern. The maximum size of each light shall be 3¼ inches high by 3¼ inches wide by 3¼ inches deep and shall be equipped with an integral mounting bracket and wiring harness pigtail with connector. OEM chassis wiring and dash switch shall be used for installation if so equipped; otherwise the lights shall be installed with a relay and dash-mounted switch. Any mounting fasteners used for these lights shall not damage the hose stored in the bumper hose tray. The dash switch shall be labeled “AUXILIARY LIGHTS, OFF HIGHWAY USE ONLY.” Rigid Industries™ Dually D2 Diffusion lights or equivalent shall be installed.

2.10 Rear View Backup Camera System

2.10.1 If not provided by the chassis manufacturer, a rear view backup camera system shall be installed in a position on the rear of the apparatus. The backup camera shall consist of the following:

2.10.1.1 A rear view backup camera and display shall be provided. The display shall have a minimum display measurement of 7 inches diagonally and be factory installed in the dash. The backup camera shall be high durability and able to withstand harsh vibration;

IP69K rated; and able to withstand 7Gs of force. The camera shall be shipped loose for installation by the apparatus builder.

2.11 Tire Pressure Monitoring System (TPMS)

2.11.1 If not provided by the chassis manufacturer, a tire pressure monitoring system shall be installed. Aftermarket tire pressure monitoring systems shall be approved by the government prior to installation. Considerations for the approval of aftermarket solutions will be quality, durability, warranty, repair service, and savings to the Government.

3 — Traffic Warning Systems

3.1 Traffic Warning Systems

3.1.1 Requests for equivalent products shall be considered. Considerations for the approval of equivalent products will be quality, durability, warranty, repair service, and savings to the Government. Any requests for substitution of equivalent products must be approved by the Government in writing.

3.1.2 The following traffic warning systems shall be provided and installed on the completed apparatus by the apparatus builder:

3.2 Electronic Siren

3.2.1 One Whelen® brand, CenCom Core™, or equivalent, electronic siren, switching and rear directional controller shall be provided and mounted in the cab center console in a location convenient to both the driver and the officer. The siren shall have four basic siren tones:

manual, wail, yelp and hi-lo, as well as an electronic air horn, radio rebroadcast capability and a public address system. The siren controller shall be powered from the “Emergency Master” switch.

3.2.2 Center switches on the CenCom Core™ siren/switch controller shall be labeled the following:

• Auxiliary Switch “A” – Left Alley

• Auxiliary Switch “B” – Right Alley

• Auxiliary Switch “C” – Front Flood

• Auxiliary Switch “D” – Rear Scene

• Auxiliary Switch “E” – Left Scene

• Auxiliary Switch “F” – Right Scene

• Auxiliary Switch “G” – Ground

• Auxiliary Switch “H” – Map

3.3 Speaker

3.3.1 One Whelen® brand, Model # SA315P 100-watt, non-corrosive, black nylon/composite siren speaker, with speaker bracket shall be provided and mounted behind the driver's side of the front bumper. The speaker shall be wired to the specified electronic siren controller.

3.4 Forward Upper Zone A/B/D Lightbar

3.4.1 One L.E.D. lightbar shall installed on the cab roof, facing forward. The light bar shall be 58 inches wide. Lightbar shall consist of eight dual-color flashing L.E.D. modules and two single color steady burning red L.E.D. modules, four front spot light L.E.D. modules Lightbar shall be programmed to specifications provided by the Government. Whelen® brand Liberty II™ Duo+™ model L.E.D. lightbar configuration number BBoDDDD-USDA- CB, or equivalent meets this requirement.

3.4.2 The lightbar shall be permanently mounted to the cab roof and wired to the “Lightbar” switch in the cab center console. The two forward facing “takedown” modules shall be interlocked with the application of the emergency brake, placing the apparatus in blocking mode and disabling the modules as such.

3.4.3 Diagram — L.E.D. Lighting Locations and Flashing/Steady Configuration

3.5 Aft Upper Zone B/D Warning Lights

3.5.1 Two Whelen® brand, Model # M6R with M6FC, or equivalent, red L.E.D. warning lights, with mounting flanges, shall be provided at the upper rear corners of the body, side-facing, one on each side of the body. The lights shall be wired to the CenCom Core™ slide switch on the cab center console.

3.6 Upper Zone C Warning Lights

3.6.1 One amber, L.E.D. warning light, with mounting flange, shall be provided at the upper rear driver's side outboard corner of the rear of the body, rear-facing. The light shall be wired to the “Rear Amber” switch on the cab center console. Whelen® brand, Model # M9A with chrome flange M9FC, L.E.D. warning light, or equivalent, shall be installed.

3.7 Lower Zone A Warning Lights

3.7.1 Two red L.E.D. warning lights, with mounting flanges, shall be provided and mounted in the lower outboard corners of the cab grille, forward-facing, one on each side. The lights shall be wired to the “Warn Lights” switch on the cab center console. Whelen® brand, Model # M7R with M7FC, L.E.D. warning lights, or equivalent, shall be installed.

3.8 Forward Lower Zone B/D Warning Lights

3.8.1 Two ½ red, ½ white, side-by-side, L.E.D. warning lights, with mounting flanges, shall be provided and mounted on the sides of the chassis tilt hood, as low and as far forward as possible, side-facing, one on each side. The lights shall be wired to the Whelen® CenCom Carbide™ siren switch or equivalent on the cab center console. Whelen® brand, Model # M7D with M7FC, L.E.D. warning lights, or equivalent, shall be installed.

3.9 Lower Zone C Warning Lights

3.9.1 Two red L.E.D. warning lights shall be provided at the lower rear of the body in the bottom position of a common housing with the DOT lights, rear-facing, one on each side. The lights shall be wired to the Whelen® CenCom Core™ siren switch on the cab center console.

Whelen® brand, Model # M6R with M6FC, L.E.D. warning lights, or equivalent, shall be installed.

3.10 Air Horn

3.10.1 One 15-inch air horn shall be provided and mounted under the hood on the passenger's side. One foot switch shall be provided on the driver's side cab floor, and one momentary pushbutton switch shall be provided on the upper right corner of the officer's side top surface of the cab center console. A Buell™ brand, Model #1063 air horn, or equivalent, shall be installed.

3.11 Headlight Flasher

3.11.1 One solid state headlight flasher shall be installed and wired for daytime operation. The flasher shall be a multipurpose type with a high-beam activated cut out option. The flasher shall be wired to the Whelen® CenCom Core™ siren switch “Wig Wag” switch on the cab center console, through the parking brake valve, so that it is disabled when the parking brake is applied. A headlight flasher that meets these requirements is the Whelen® brand, Model UHF2150A flasher.

4 — Chassis Additions and Modifications

4.1 Additional Equipment Installation

4.1.1 The following additional equipment shall be installed on, and modifications performed to, the specified cab and chassis by the apparatus manufacturer:

4.2 Apparatus Fluid Types and Quantities

4.2.1 A permanently mounted label, showing the recommended fluid types and quantities for the apparatus chassis and associated components, shall be provided in the apparatus cab interior near the driver's seating position.

4.2.2 This label shall list the recommended fluid types and quantities for the following components:

• Chassis Engine Lubricant

• Chassis Engine Coolant

• Chassis Power Steering Fluid

• Chassis Transmission Fluid

• Chassis Drive Axle Lubricant

4.3 Seating Capacity

4.3.1 The completed crew carrier apparatus shall be designed to have a fully enclosed seat with an approved seat belt for each occupant. The term “fully enclosed” shall mean four sides, a top and a bottom, with an appropriate door for easy entrance to and exit from the seating position.

4.3.2 A warning label, listing the seating capacity of the completed apparatus, shall be provided in the apparatus cab interior. This label shall be located so that it is visible from all seating positions.

4.3.3 This apparatus shall have a seating capacity of ten personnel; two in the cab and eight in the crew compartment.

4.4 Seat Belt Warning

4.4.1 A warning label, stating: “DANGER- Personnel Must Be Seated And Seat Belts Must Be Fastened While Vehicle Is In Motion Or DEATH OR SERIOUS INJURY MAY RESULT,” shall be provided in the apparatus cab interior and crew compartment area. This label shall be located so that it is visible from all seating positions.

4.5 Vehicle Height Warning

4.5.1 A warning label, listing the overall height, length and GVWR of the completed apparatus, shall be provided in the apparatus cab interior. This label shall be located so that it is visible from the driver's seating position.

4.6 Final Stage Manufacturer Vehicle Certification

4.6.1 A Final Stage Manufacturer vehicle certification label shall be provided and installed in the apparatus cab driver's door jamb area.

4.7 Noise Hazard Warning

4.7.1 A warning label, stating: “WARNING: Noise Hazards Occur During Siren Operation,” shall be provided and installed in the apparatus cab interior. This label shall be located so that it is visible from all seating positions.

4.8 Air Filter Ember Protection Screen Warning

4.8.1 A warning label, stating: “This apparatus is equipped with an air filter ember protection screen; routine inspection is required,” shall be provided and installed in the apparatus cab interior. This label shall be located so that it is visible from the driver's seating position.

4.9 Cab Console

4.9.1 The cab shall be equipped with a sloped operator's control console located between the front driver's and officer's air ride seats. The console shall be fabricated from steel, and painted with a matte black finish.

4.9.2 The Whelen® CenCom Core™ siren controller shall be installed on the cab console.

4.9.3 A low battery indicator RED light shall be installed and be clearly visible from the driver's seat.

4.9.4 An air horn push button shall be installed on the cab console.

4.9.5 The console shall contain one flexible map light; two 12-volt power outlets; four USB charging outlets; and two 120-volt alternating current power outlets powered by the inverter.

The 12-volt power outlets shall be located one at each lower corner of the console. The 120-volt alternating current outlets are not required to be located on the top of the console and may be located in a location convenient to the occupant seated in the passenger seat.

4.10 Center Console Aft Storage

4.10.1 A compartment for storage of items, such as maps and hand-held radios, shall be provided and attached directly behind the center console. The storage compartment shall be fabricated from steel and painted with a matte black finish. Configuration and size of the compartment shall be as specified by the Government. The height and width shall not exceed the cab console. The storage compartment shall be configured so as to be easily removable for access to the console inspection panel.

4.11 Front Tow Hooks

4.11.1 Two original equipment front tow hooks shall be supplied with the chassis from the chassis manufacturer.

4.12 Tow Eyes

4.12.1 Two heavy-duty tow eyes shall be provided at the rear of the apparatus, below the rear step. The tow eyes shall be mounted to the chassis frame.

4.13 Front Fenders, Rubber

4.13.1 An extruded black rubber fenderette shall be installed on each front wheel well opening on the chassis tilt hood.

4.14 Mud Flaps

4.14.1 One pair of flexible rubber mud flaps shall be provided on both sides of the apparatus body behind the rear wheels. The mud flaps shall not bear company logo.

4.14.2 The mud flaps shall extend down far enough to be effective but shall not allow the flaps to become entangled with the rear tires when the apparatus is backing up.

4.15 Exhaust System

4.15.1 The exhaust system shall be routed to the rear of the crew compartment behind the rear most window as required per FMVSS regulation. The exhaust piping shall be the same size as the original, and shall be routed and supported as required to provide maximum ground clearance, clear of the vehicle suspension, axle, frame, hoses, wiring, brake canisters, spare tire and other vehicle components.

4.16 Heat Protection

4.16.1 The exhaust after-treatment system shall be sufficiently shielded or wrapped to protect the underside of the chassis cab during active regeneration. Heat from regeneration shall not be detected by personnel seated inside the cab.

4.17 Air Line, Fuel Hose, Electrical Harness and Connector Protection

4.17.1 All air lines, fuel lines and electrical harnesses below the chassis frame rails shall be protected with a fire proof sleeve. All protected and wrapped lines shall have continuous coverage, to include the line to tank connections.

4.18 Cabin Air Ember Guard

4.18.1 The cabin air filter shall be protected by an ember guard with a maximum mesh opening of

0.039 inches.

4.19 Auxiliary Air Outlet

4.19.1 A quick disconnect female auxiliary air outlet shall be provided in the driver's side 80 inches wide by 17 inches high by 18 inches deep compartment. An air protection valve (90 pounds per square inch) shall be placed at the OEM truck air tank at the highest possible level, followed by a shut off valve.

4.20 Under Cab Storage Compartment

4.20.1 One aluminum storage compartment, mounted under the passenger cab step, shall be provided if chassis space allows. Storage compartment door shall be diamond plate, with a vertical hinge and compression latch.

5 — Crew Carrier Body Description

5.1 Body Design

5.1.1 The crew carrier body shall be designed for fire service operations only. Commercially designed bodies intended for use in other vocations or applications are unacceptable in quality, construction, design or durability. The crew carrier body module shall utilize a full welded sub-frame, independent of the chassis.

5.2 Structural Integrity

5.2.1 A structural integrity test report and a certificate of conformance shall be provided by an independent third-party laboratory or test facility certifying that the body complies with the roof and side load requirements of AMD 001, Ambulance Body Structure Static Load Test as follows:

5.2.2 Roof Load Test: The body shall withstand a force equal to 2.5 times the curb weight of the vehicle applied to the roof of the body. The downward vertical movement at any point on the roof application plate shall not exceed 5.13 inches. Each exterior exit door of the vehicle shall be capable of opening and closing, and all emergency escape windows shall open, during the full application of the force and after release of the force. No structural damage to any load bearing or supporting members (i.e., torn or broken material, broken welds, popped or sheared body rivets, bolts and/or fasteners) shall be evident during the application of the force and after the release of the force.

5.2.3 Side Load Test: The body shall withstand a force equal to 2.5 times the curb weight of the vehicle applied to either the driver or passenger side of the body. The movement at any point on the side application plate shall not exceed 5.13 inches. The rear door of the vehicle shall be capable of opening and closing, and the roof emergency escape shall open, during the full application of the force and after release of the force. No structural damage to any load bearing or supporting members shall be evident during the application of the force and after the release of the force.

5.2.4 Testing shall be performed on a body that is structurally identical to production units. The test report shall include video and photo documentation of the testing. Computer simulations or analysis (e.g., a finite element analysis) is not an acceptable substitute for testing. Test articles are considered maximum stress units and shall not be used for production.

5.2.5 After certification, the contractor shall notify the Government immediately in writing when a material changes in any way, when a major manufacturing process changes in any way, or when a manufacturing location changes. The need for recertification shall be determined by the Government when there are changes to the product or this specification.

5.3 Body Construction

5.3.1 The body module shall be comprised of a welded superstructure framework consisting of vertical and horizontal components fabricated from structural steel tubing. The superstructure framework is intended to protect occupants and the integrity of the emergency escapes and shall as a minimum include the entire perimeter of crew compartment envelope, the perimeters of the four escape windows, the roof escape, the rear door, and the cab to body pass-through. The vertical framework at the front and rear of the body module shall extend the height of the body from the sub-frame to the superstructure roof. In addition to the perimeter framework at the front and rear of the body module, the framework shall also include, as a minimum, a third transverse structural member across the roof and extending the height of the body from the superstructure roof to the sub-frame, positioned vertically between the two side windows and storage compartments. Offsetting or staggering of the required vertical framework is not acceptable.

Fabrication of the structural framework and framework members from formed sheet steel is not acceptable.

5.3.2 Sheet aluminum bodies, extruded aluminum bodies, or bodies that are of bolted or riveted body construction shall not be acceptable. The superstructure framework and the body sub-frame shall be a unitized design to form a single weldment assembly for structural integrity.

All welding, metal work and fabrication shall be completed with the highest degree of quality and precision. All fasteners utilized in the construction of the body module shall be high quality corrosion resistant and suitable for its intended use. Any threaded fasteners utilized shall be machine screw type, and all holes shall be properly sized and tapped to create threads to receive them. Threaded expanding inserts shall be utilized where required. All fasteners shall utilize a locking method to prevent loosening from vibration. Strict attention shall be given to the elimination of hazards to personnel and equipment, such as rough edges, sharp corners, or protruding nuts and bolts. All exposed welded corners on aluminum tread plate shall be polished to a bright finish. All exposed corners shall be radiused and deburred. Where fasteners may come into contact with personnel or equipment, acorn type nuts or countersunk fasteners shall be utilized. All structural seams shall be fully seam welded, with all other body seams being caulked prior to painting.

5.3.3 The roof shall be 16-gauge minimum galvanneal ASTM A-60 steel sheet. Roof seams shall be continuously welded at the corners where they intersect with the lower rear and front body panels. The balance of the roof seams shall be skip welded and sealed to limit distortion and not remove protective rust inhibiting zinc coating from sheet metal.

5.3.4 The body shall be completely modular in design, thereby allowing its transfer to a new chassis, without cutting or welding, in the event of an accident or chassis replacement.

5.4 Body Sub-Frame

5.4.1 The body sub-frame shall be fabricated from structural steel tubing and/or channel. The sub-frame structural material shall be appropriately sized to withstand the static and dynamic loads and stresses during the apparatus' operation on unimproved road conditions at maximum allowable payload, plus allowing for the industry's standard safety factor. The sub-frame design shall be a nested, NOT stacked, sub-frame, or similar, to allow for the lowest vertical center of gravity that can be achieved. The longitudinal structural members and the cross-members shall be nested and welded to each other. They shall be located such to provide maximum structural stability in the stated operating conditions.

5.4.2 The sub-frame shall be mounted to the chassis frame rails utilizing spring mounts at the front mounting points and shear plates at the rear mounting points.

5.5 Body Materials

5.5.1 All materials utilized in the fabrication of the body shall be of the correct type, alloy, and thickness to withstand the intended usage and provide protection against cracking, corrosion or metal fatigue. All materials utilized shall be of open stock origin, available to all apparatus manufacturers and commonly available through local sources, for the rapid and economical repair or modification of the body. Any use of proprietary parts or materials in the construction of the body shall be unacceptable, due to the potential for delays or difficulties in the event future repairs or service become necessary.

5.6 Body Mounting

5.6.1 The crew carrier body module shall be mounted utilizing spring mounts and shear plate mounts to allow for a degree of independent movement between the body frame and the chassis frame. The body shall be mounted at six mounting points. There shall be four spring mounting points at the forward end of the body. There shall be two shear plate type mounting points at the aft end of the body module.

5.6.2 The mounts at the forward end of the body shall be comprised of a two-piece design, fabricated from steel plate, with the upper section welded to the body module sub-frame and the lower section bolted to the exterior vertical surface of the chassis frame rails. The upper mount section shall be designed to nest within the lower mount section. The body mount sections shall be aligned and connected by properly sized Grade 8 bolts, equipped with an appropriate tension rating spring, flat washers and a locking nut.

5.6.2.1 Four mounts of this design shall be provided, two on each side of the body.

5.6.3 The mounts at the aft end of the body shall be comprised of vertical steel plates minimum that are welded to the body sub-frame and bolted to the exterior vertical surface of the chassis frame rails. These mounts shall extend rearward horizontally to incorporate the rear step supports and rear tow eyes.

5.6.3.1 Two mounts of this design shall be provided, one on each side of the body.

5.6.4 The body may be isolated from the chassis frame by using ¾ inch thick rubber, vulcanized to ¼ inch steel plate. The steel plate shall be welded or otherwise permanently affixed to the body frame.

5.6.5 All mounting nuts, bolts, and washers required for complete crew carrier body installation shall meet or exceed SAE and industry standards. All of the mounting hardware shall be plated to reduce corrosion. All nuts shall be Stover™ style lock nuts.

5.6.6 A secondary retention system, consisting of four 0.375-inch diameter minimum woven aircraft cable loops with bolted clamp connector, shall be installed to prevent the crew carrier body and frame from completely separating from the chassis frame in the event of an accident where the primary system fails. Two cable loops shall be installed at the forward end of the body, one on each side, and two cable loops shall be installed at the aft end of the body, one on each side. Any wiring, wiring harnesses or air lines adjacent to or in close proximity to the cables shall have adequate sheathing to prevent damage.

5.7 Rear Step/Bumper

5.7.1 A full-width DOT-compliant rear step/bumper assembly shall be provided at the rear of the crew carrier body for assistance in entering or exiting the crew compartment. The step assembly shall have a tread surface fabricated from a minimum of 10 gauge steel plate with a structural steel support framework. The rear step/bumper assembly shall be bolted directly to the chassis frame rails for strength, and all exterior surfaces of the step shall be finished with black non-skid Dura Coat™ material, or equivalent. The rear step/bumper assembly shall have a depth of approximately 8.00 inches.

5.7.2 A steel fold down step, fabricated from grip strut tread and steel flat bar, shall be provided in the center of the bumper to achieve a maximum distance of 24 inches from the ground to the first step. The rear step/bumper assembly shall be completely modular in design, and shall be capable of being unbolted and removed for repair or replacement. The step shall rotate up and towards the bumper 270° when not in use, with the step sides horizontal and flush to the top step and the step recessed into a slot in front of the top step when stored.

The step shall be positively secured in the stowed position by means of a finger pull slam latch mounted on the curbside of the step. The step/bumper design and installation shall be such to allow for a minimum departure angle of 20 degrees.

5.7.3 A warning plate shall be affixed to the rear of the crew carrier body in a conspicuous place.

The warning plate shall read: “WARNING: DO NOT RIDE ON REAR STEP WHILE

VEHICLE IS IN MOTION. DEATH OR SERIOUS INJURY MAY RESULT”

5.8 Rear Skid Plate

5.8.1 Two skid plates shall be installed on the rear underside of the body between the spare tire and the rear bumper. The skid plates shall span from each outside body edge, wraps around to protect body sides, to the frame rail and wrap under and flush to the rear

5.9 Body Protection Panels

5.9.1 The vertical corners and bottom edges of the body shall be covered with a 2 inch wrap of aluminum tread plate. The outboard lower front portion of the body shall be overlaid with a polished aluminum tread plate protection panel covering, approximately 24 inches wide by 44 inches high each side.

5.9.2 Body scuff guards shall be provided and installed on the bottom edge of all compartment door openings.

5.10 Body Dimensions

5.10.1 The crew carrier body shall have overall exterior dimensions of 100 inches wide by 90 inches high by 168 inches long ± 0.25 inches.

5.11 Compartmentation

5.11.1 The compartments may be constructed integral with the rest of the body or may be constructed independently as modular units. All compartment walls and floors shall be fabricated from 16-gauge minimum galvanneal ASTM A-60 steel sheet. The compartments shall either be framed using a structure of steel members (steel tubing, angle and/or channel) or constructed using sheet steel formed into structural shapes to meet the specified compartment dimensions. The side compartments shall be welded together and permanently welded to the body module superstructure. The compartment fronts shall be formed so as to have a channel around the perimeter of the opening. The channel shall be continuous and be seal welded at each corner to make a weather tight door seal channel.

5.11.2 All compartment interiors shall be free of exposed electrical harnesses.

5.11.3 All enclosed compartments shall be water and dust tight.

5.11.4 All compartments shall be as large as possible, as determined by the design of the apparatus.

5.11.5 All compartments shall be attached to the crew carrier body sub-frame and superstructure only, in order to maintain a truly modular design. Compartments shall not be attached directly to the chassis frame rails.

5.11.6 The approximate compartment sizes required are listed below:

5.12 Driver's Side Compartments

5.12.1 One vertical compartment shall be provided at the forward corner of the lower side body section of the crew carrier body. The compartment shall be accessible through a vertically-hinged door, with the hinged side of the door toward the front of the body. The compartment shall be equipped with steel Unistrut™ channels for shelves. There shall be a segregated battery storage compartment with a separate latching access door in the bottom inboard wall of the compartment to house two batteries. Modifications to this compartment may be required to accommodate the Diesel Exhaust Fluid (DEF) tank supplied by the chassis manufacturer. Modifications to this compartment shall be approved by the Government.

5.12.2 Approximate Compartment Size: 34 inches wide by 43 inches high by 18 inches deep ±0.25 inches.

5.12.3 One vertical compartment shall be provided directly aft of the compartment at the forward corner of the lower side body section of the crew carrier body, directly forward of the rear wheels. The compartment shall be accessible through a vertically hinged door, with the hinged side of the door toward the rear of the body. The compartment shall be equipped with steel Unistrut™ channels for shelves. There shall be a segregated battery storage compartment with a separate latching access door in the bottom inboard wall of the compartment to house two batteries.

5.12.4 Approximate Compartment Size: 34 inches wide by 43 inches high by 18 inches deep ±0.25 inches.

5.12.5 One horizontal compartment shall be provided directly aft of the compartment forward of the rear wheels of the crew carrier body. The compartment shall be accessible through a horizontally hinged overhead lift-up door. The compartment shall be equipped with steel Unistrut™ channels for shelves. Two door latches and handles shall be provided on the lift-up door.

5.12.6 Approximate Compartment Size: 80 inches wide by 17 inches high by 18 inches deep ±0.25 inches.

5.12.7 One horizontal compartment with pull out drawer shall be provided, spanning the wheel well. A drawer of maximum size shall be installed in this compartment. The drawer shall be horizontally mounted with a slider mechanism and have a stop to keep the drawer from retracting when on uneven ground. It shall have five 4-inch-high aluminum adjustable dividers. The drawer shall have a hinged lid of ⅛-inch aluminum that, when the lid is closed and the drawer is open, can be used as a work area.

5.12.8 Approximate Compartment Size: 54 inches wide by 6 inches high by 18 inches deep ±0.25 inches.

5.12.9 One compartment shall be provided directly aft of the rear wheels of the crew carrier body to store fuel cans and drip torches. The compartment shall be accessible through a vertically hinged door, with the hinged side of the door toward the front of the body.

Machine stamped ventilating louvers shall be furnished at the inboard wall of this compartment. The compartment shall be equipped with steel Unistrut™ channels for shelves. One stainless steel drip tray, of maximum length and width, shall be provided on the floor of the compartment with a 1-inch full perimeter lip.

5.12.10 Approximate Compartment Size: 26 inches wide by 26 inches high by 18 inches deep (26 inches deep below the floor) ± 0.25 inches.

5.12.11 One horizontal compartment shall be provided aft of the drip torch compartment, at the lower rear of the crew carrier body. The compartment shall be accessible through a vertically hinged door, with the hinged side of the door toward the rear of the body. The compartment shall be equipped with steel Unistrut™ channels for shelves.

5.12.12 Approximate Compartment Size: 20 inches wide by 26 inches high by 18 inches deep (26 inches deep below the floor) ± 0.25 inches.

5.13 Passenger's Side Compartments

5.13.1 One vertical compartment shall be provided at the forward corner of the lower side body section of the crew carrier body. The compartment shall be accessible through a vertically-hinged door, with the hinged side of the door toward the front of the body. The compartment shall be equipped with steel Unistrut™ channels for shelves.

5.13.2 Approximate Compartment Size: 34 inches wide by 43 inches high by 18 inches deep (26 inches deep below the floor) ± 0.25 inches.

5.13.3 One vertical compartment shall be provided directly aft of the compartment at the forward corner of the lower side body section of the crew carrier body, directly forward of the rear wheels. The compartment shall be accessible through a vertically hinged door, with the hinged side of the door toward the rear of the body. The compartment shall be equipped with steel Unistrut™ channels for shelves.

5.13.4 Approximate Compartment Size: 34 inches wide by 43 inches high by 18 inches deep (26 inches deep below the floor) ± 0.25 inches.

5.13.5 One horizontal compartment shall be provided directly aft of the compartment forward of the rear wheels of the crew carrier body. The compartment shall be accessible through a horizontally hinged drop down door. The compartment shall be equipped with steel Unistrut™ channels for shelves. Two door latches and handles shall be provided on the drop-down door.

5.13.6 Approximate Compartment Size: 80 inches wide by 23 inches high by 18 inches deep ±

0.25 inches.

5.13.7 One horizontal compartment shall be provided directly aft of the rear wheels of the crew carrier body. The compartment shall be accessible through two vertically hinged barn doors, with the D-ring latch installed on the primary door toward the front of the body. The secondary door shall be equipped with a barrel bolt installed on the interior panel of the door.

5.13.8 Approximate Compartment Size: 46 inches wide by 20 inches high by 18 inches deep (26 inches deep below the floor) ± 0.25 inches.

5.14 Compartment Doors – Steel Overlap Type

5.14.1 All compartment doors shall be recessed into the crew carrier body sides, with overlapping outer door panels for a secondary seal. Their construction shall be a double panel design with 14-gauge steel outer lap panel and an 18 gauge steel inner panel. The inner panel shall be welded to the outer panel and a full width reinforcement channel shall be attached to both the inner and outer panels. No welds shall be visible on the outer door panel, door pan sides or inner door panel. The door edges shall be contoured, with radiused corners, to provide a smooth, snag-free perimeter.

5.14.2 The door design shall be such to allow for servicing and/or replacement of the latch mechanism.

5.14.3 All compartment door opening channel perimeters shall be fitted with black automotive grade, closed-cell, Neoprene® “D” section open center door seals with adhesive backing.

All door outer panels shall have automotive-grade, closed-cell, self-adhesive, “ribbed” type gaskets fitted to the overlap surface for a secondary seal.

5.15 Door Latches and Hardware

5.15.1 All compartment door latch assemblies shall be installed with threaded fasteners, shall not be welded, and shall be easily removable through the outer panel of the door for servicing or replacement. All door latch assemblies shall be of a flush-mount, rotary “D-Handle” design, with all external components fabricated from polished stainless steel. All latches shall be of a slam-type design, with a two-point latching operation. Matching striker bolts shall be utilized with all latch assemblies. All striker bolts shall have slotted mounting holes and shall be attached with bolts to captive steel plates in the body structure for strength and ease of adjustment. Welded striker bolts or plates shall not be acceptable.

5.15.2 The following door latch assemblies meet these requirements:

5.15.3 Compartment Door Handle Assembly – Hansen™ brand, Model # 279L SS

5.15.4 Compartment Door Latch Assembly – Hansen™ brand, Model # 550

5.15.5 Striker Bolt Assembly – Hansen™ brand, Model # 551S

5.15.6 All hardware shall be corrosion resistant and suitable…