Attachment_B_-_Specification_4210-5617_AS_BUILT.pdf

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State of California Specification

Emergency Crew Transport Vehicle (ECT)

4210-5617 Attachment B

Document Summary Detail Type Detail Event ID N/A Commodity Emergency Crew Transport (ECT) *As-Built* Attachment B Addendum N/A Group-Class N/A Bid Specification 4210-5617 Revision Level N/A Revision Date *4/5/2023* Agency Name California Department of Forestry and Fire Protection

Revision History

Bid Spec

Rev Level

Revision Date

Author Summary of Changes

4210-5617 N/A 7/18/2022 Benjamin Middleton Initial Release *4210-5617* *4/5/2023* *William Minton* *As-Built (Changes in Red)*

Contents Document Summary Revision History

1.0 SCOPE

2.0 APPLICABLE LAWS and INDUSTRY STANDARDS

2.1 LAWS, REGULATIONS and INDUSTRY STANDARDS:

3.0 CAB AND CHASSIS TECHNICAL REQUIREMENTS

3.1 Cab/Chassis, Dimensions and Weights:

3.2 Front Axle

3.3 Rear Axle

3.4 Driveshaft

3.5 Brakes

3.6 Air Dryer

3.7 Parking Brake

3.8 Air Compressor

3.9 Brake Hose

3.10 Cab and Doors

3.11 Cab Complement

3.12 Instruments and Gauges

3.13 Side Mirrors

3.14 Interior Seats and Trim

3.15 Electrical System

3.16 Engine

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3.17 Auxiliary Braking

3.18 Transmission

3.19 Cooling System

3.20 Fan Drive

3.21 Frame

3.22 Suspension

3.23 Wheels

3.24 Tires

3.25 Fuel System

3.26 Exhaust System

3.27 Cab Paint

4.0 BODY REQUIREMENTS

4.1 General

4.2 Exterior Dimensions

4.3 Interior Dimensions

4.4 Body Structure

4.5 Rub Rail

4.6 Framing

4.7 Exterior Roof Skin

4.8 Drip Rail

4.9 Exterior Side Wall Skin

4.10 Body Seams

4.11 Insulation

4.12 Flooring

4.13 Windows

4.14 Privacy Screens

4.15 Emergency Escape Hatch

4.16 Rear Crew Door

4.17 Wheel Wells

4.18 Body Mounting

4.19 Interior Body Fasteners

5.0 COMPARTMENTS

5.1 Compartment Dimensions

5.2 General Construction

5.3 Compartment Door Construction

5.4 Door Locks/Latches

5.5 Door Checks

5.6 Compartment Shelves/Trays

5.7 Underbody Compartments

5.8 Interior Storage Compartments

5.9 Exterior Main Body Compartments

5.10 Interior Overhead Storage Compartments

5.11 In-Cab Seat Pedestal

5.12 In-Cab Center Console

5.13 Potable Drinking Water Containers

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Emergency Crew Transport Vehicle (ECT)

6.0 Miscellaneous Components

6.1 Spare Tire Carrier

6.2 Rear Entrance Ladder

6.3 Rear Bumper

6.4 Rear Tow Eye

6.5 Front Tow Hooks

6.6 Brake Components

6.7 Air Horn

6.8 Air Intake Screen

6.9 Driveline Hoops

6.10 Mud Flaps

6.11 Air Coupling

6.12 Chock Blocks

6.13 License Plate Mounting

6.14 Fuel System

7.0 Body Interior

7.1 Interior Walls and Ceilings

7.2 Crew Air Conditioning/Heater

7.3 Exhaust Vents

7.4 Crew Seats

8.0 Lights and Electrical System

8.1 Wiring

8.2 Electrical Interface Panel

8.3 Master Disconnect Switch

8.4 USB Charge Ports

8.5 Handheld Portable Radio Charge Circuit

8.6 Switches/Solenoids/Pilot Lights

8.7 Dome Lights

8.8 Rear Crew Door Warning

8.9 Crew Compartment Warning

8.10 Open Compartment Door Warning

8.11 Compartment Lighting

8.12 LED Area Lighting

8.13 Tail, Stop and Turning Lights

8.14 Clearance Marker Lights

8.15 Reflectors

8.16 Back-Up Lights

8.17 License Plate Lights

8.18 Ground Lights

8.19 Map Light/Reading Light

8.20 Mobile Radio

8.21 Radio Antenna

8.22 Intercom

8.23 AM/FM Radio Speakers

8.24 High Idle Switch

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8.25 Back-up Cameras

8.26 Back-Up Alarm

8.27 Ground Straps

9.0 Emergency Lighting General

9.1 General

9.2 LED Upper Zone Lighting

9.3 LED Lower Zone Lighting

9.4 Rear Traffic Advisor

9.5 Lighting Operation

9.6 Audible Warning Controls

9.7 Siren Speaker

9.8 WIG WAG

10.0 Paint

10.2 Materials

10.3 Cab, Chassis and Body Structure

10.4 Pre-Finish Painting

10.5 Body Exterior

10.6 Cab Roof

10.7 Compartment Interiors

10.8 Interior

10.9 Undercoating

10.10 Exterior

11.0 Additional Requirements

11.2 Battery Charger

11.3 Automatic Vehicle Location System

Only a single continuous run shall be accepted

11.4 Graphics

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1.0 SCOPE

The California Department of Forestry and Fire Protection (CAL FIRE) protects the State of California from fires, responds to emergencies, protects and enhances the forest, range and watershed values while providing social, economic and environmental benefits to the citizens of rural and urban California.

This specification describes general requirements for the complete construction of Emergency Crew Transport (ECT) vehicles. ECT bodies shall be fabricated and installed on contractor supplied diesel powered cab and chassis. The completed vehicles shall be designated as California Department of Forestry 17 Passenger Emergency Crew Transport Vehicles.

The Emergency Crew Transport Vehicles will be used by CAL FIRE to respond to emergencies, which may include extensive traveling on mountain roads and forest truck trails that will impose extreme stress on all components. Safety of the fire crew shall be of the utmost concern in all phases of construction. The highest quality materials, state of the art components, including wiring, shall be utilized in the design and construction of the finished Emergency Crew Transport described in this bid solicitation.

2.0 APPLICABLE LAWS and INDUSTRY STANDARDS

The following standards, law and regulations of the issue in effect on the date of the Invitation for Bid form a part of this specification to the extent specified herein. The ECT is required to meet all regulations, standards and laws including revisions, at time of ECT acceptance and through the term of the contract:

2.1 LAWS, REGULATIONS and INDUSTRY STANDARDS:

2.1.1 Federal Motor Vehicle Safety Standards (FMVSS)

2.1.2 Code of Federal Regulations (CFR), Title 49, Chapter V-National Safety Bureau

2.1.3 California Code of Regulations (CCR), Title 13

2.1.4 California Vehicle Code (CVC)

2.1.5 California Health and Safety Code

2.1.6 California Air Resources Board Regulations (CARB)

2.1.7 Original Equipment Manufacturer (OEM) Body Builder Standards and Guidelines

2.1.8 National Fire Protection Association (NFPA) #1901 latest edition as it pertains

2.1.9 NFPA #1906 latest edition as it pertains

2.1.10 Society of Automotive Engineers (SAE) standards where applicable

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2.1.11 Part 15 of the Federal Communications Commission (FCC) Rules

EXEMPTIONS: CAL FIRE shall provide exemptions for certain items as specified in the attached Exemption No. MC 94-2 to meet the requirements of Title 13 of the California Administrative Code, Chapter II, Subchapter 6.5, Paragraph 1267, Item 2.

The final completed vehicle certification is the responsibility of the manufacturer constructing the body described herein. A plate identifying the manufacturer, tare weight, gross vehicle, date of manufacture and all other information as specified in CFR. Title 49, Part 567 section 567.4 and 567.5 as applicable shall be attached to the vehicle.

Should a conflict arise between any of these standards and this specification CAL FIRE will determine as to which standard or specification will be in effect.

Details regarding any conflicts between the specific standards and compliance will be finalized at the pre-construction conference or during the development process.

Any test equipment required, or expense incurred for the Certification Tests shall be borne by the Contractor supplying this equipment.

3.0 CAB AND CHASSIS TECHNICAL REQUIREMENTS

3.1 Cab/Chassis, Dimensions and Weights:

• International MV Model SBA or equivalent (set back front axle) shall be provided

4 X 2 chassis, two (2) door standard conventional cab

• Manufacturer's gross vehicle weight rating (GVWR) to be not less than

* 35,000* pounds

• Wheelbase: 186 – 191 inches

• Back of cab to centerline of rear axle to be 119 – 124 inches, clear and clean

• Cab to end of frame to be not less than 205 inches

• Bare chassis and cab curb weight with specified tires to be maximum 13,000 pounds

• Cab height not to exceed 113 inches unloaded

• *Chassis will be equipped with Stability Control (International MV)*

3.2 Front Axle

The front axle shall have a minimum rating of 12,000 pounds. The front axle shall be equipped with OEM hydraulic power steering. Axle hubs shall be provided with oil bath lubrication with synthetic lube oil. Clear hub covers will be supplied so that operators can visually inspect the hub oil level.

3.3 Rear Axle

Full floating; hypoid or spiral bevel; single reduction, rated not less than [21,000] *23,000* pounds. Axle ratio to provide for 72 mph at engine governed RPM, “0%”

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Emergency Crew Transport Vehicle (ECT) road grade. Rear axle assembly shall be provided with synthetic lube. The rear differential shall be provided with a driver controlled locking rear differential. The maximum governed road speed will be set at 68 mph. Specific gear ratio [557] *563* or equivalent shall be discussed and defined at pre-construction conference.

3.4 Driveshaft

Heavy duty automotive designed and engineered drive shafts with center support capable of handling the maximum torque developed by the engine and delivered to the transmission and other drive components in shall be used. All driveshafts shall be able to withstand the off road and highway usage of this vehicle. Safety hoops shall be installed as described in Section 6.9. *Vendor will provide drawing for locations of driveline hoops to wrap each section of driveline. See Attachments AP-00-016568 DL Hoops EXT*

3.5 Brakes

A four (4) channel, dual air Anti-lock Braking (ABS) air brake system for straight trucks with “S” cam drum brakes, automatic slack adjusters and outboard mounted drums that meets all FMVSS shall be provided. The brake shoe dimensions for the front and rear axle shall be the maximum size available for the axles specified. All brake drums and rotors shall be outboard mounted.

3.6 Air Dryer

A Bendix AD-IP (or equivalent) air dryer shall be provided. The dryer height shall be no greater than the frame rail depth. *Note: location on passenger or drivers side Frame rail. *

3.7 Parking Brake

Rear wheel spring brakes with spring brake control shall be provided. The parking brake is to be set with "pull" action and released with "push" action and shall also be properly labeled. The release control knob will be yellow in color.

3.8 Air Compressor

The air compressor shall be a minimum of 13 CFM capacity, water-cooled. The compressor air source shall be routed from the engine air cleaner and shall be located on the “pressure” side of the intake system. If this routing cannot be completed in this manner than a check valve shall be installed to ensure that the system does not have a negative pressure to the compressor.

3.9 Brake Hose

D.O.T. approved rubber brake hoses shall be provided at all brake chambers. All Synflex air hose that is routed below the frame rails shall be wrapped with a fire wrap lagging capable of withstanding flame and heat impingement of a minimum of 250°C (482°F). When any factory air lines are modified no push lock fittings will be accepted only ferrule and tube inserts with nuts.

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3.10 Cab and Doors

Shall be an OEM manufactured two (2) door standard cab with front fenders and a swept back front bumper. The cab entrance doors shall open 60° (minimum).

3.11 Cab Complement

• OEM air-conditioning with integral heater, defroster and fresh air filter

• Dual OEM Air Conditioning Compressors *the crew area air conditioning compressor shall be a TM 21 (506-889) part number pad mount style shall be provided with a ¼ inch steel bracket (pad mounted) and properly aligned pulleys. Suction side of air conditioning compressor will have a screen. Note:

TM 21 bracket to be provided by CalFire.*

• One or three piece hi-strength composite tilt hood or tilt hood and fenders with standard OEM grille

• OEM bug screen mounted behind the grille

• Cab sound Insulation package

• Black or grey rubber cab floor covering

• Tinted glass (rear windows)

• Tilt steering wheel

• Transmission quadrant selector Multi-function shift lever with selector positions marked

• Arm rest, all doors

• AM/FM radio with USB, Bluetooth capable and weather band with multiple speakers and antenna

• Two (2) adjustable sun visors

• Dual electric 2-speed windshield wipers and washers

• Dual electric horns

• Data case in each door

• Entry grab handle for each door with anti-slip rubber inserts

• Keyed ignition switch shutoff

• OEM logos or badges shall be shipped loose

• Low air (brake) pressure warning device

• Camper style rear window with center sliding window

3.12 Instruments and Gauges

• All gauges shall be in dash mounted and where appropriate, warnings shall be visual and audible.

• Indicating voltmeter

• Air pressure gauge

• Oil pressure gauge

• Engine coolant temperature gauge

• Transmission oil temperature gauge

• Fuel level gauge

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• Speedometer, with trip meter, odometer

• Intake air restriction gauge vacuum activated, meter type, resettable, Donaldson

168501-00225 (or equivalent)

• Tachometer, factory installed, dash mounted

• Electronic hour meter

3.13 Side Mirrors

Two (2) electrically adjustable, heated swing-away, reset type rear view mirror assemblies with brackets appropriate to cab structure. The mirror heads shall be one-piece frame, at least 6 inches x 14 inches, with a minimum 7.44 inches. Two (2) adjustable convex mirror mounted below the mirror head.

3.14 Interior Seats and Trim

Standard gray color vinyl upholstery shall be provided. Adjustable front hi-back bucket seats with a National 2000 (or equivalent) air ride adjustable driver seating.

There shall be safety belts/shoulder harnesses installed for each seating position, with metal-to-metal buckle, positive pelvic restraint where available. All belts and mounting must be FMVSS approved. The outside belt ends shall be equipped with OEM floor mount retractors. Three (3) point belts shall be provided for each outboard seat position. The seat belts shall be Red or Safety Orange to comply with NFPA standards

3.15 Electrical System

• Shall be 12 Volts with a heavy-duty alternator, rated at a minimum of 325 Amps, internally regulated, diode protection system and provided with the minimum features as listed:

• Heavy Duty OEM body builder wiring harness that provides separate stop/turn configuration that terminates at the end of the frame rails

• Battery disconnect switch, positive type, lever operated, mounted on the cab floor, driver’s side (OEM chassis manufacturer supplied disconnect is acceptable). See Section 8.3 for additional details if OEM disconnect switch is not provided.

• A 120 Volt, minimum 1000 Watt engine block heater (or as recommended by the engine manufacturer) and receptacle mounted below the driver’s door

• 2-Way Radio wiring with minimum 20 Amp fuse protection

• Ignition wire with 5 Amp fuse wire ends heat shrink and 10 foot coil taped to base harness

• Hand throttle, electronically controlled from within the cab

• Hi-Lo [halogen sealed beam] *LED* headlights with daytime running lights with a flash to pass feature

• Whelen Micro Pioneer or Rigid D-Series SAE 504813 fog-driving lights or equivalent switched on dash shall be installed.

• Parking lights

• Two (2) rear stop and taillights

• Instrument panel lights

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• Interior (courtesy) dome lighting, door switch operated (on both doors)

• Side marker lights

• Clearance and identification lights

• Two (2) front mounted turn signal lights

• Hazard warning light switch

• Self-canceling flashing turn signal light switch (OEM)

• Three (3) each BCI Group 3l, minimum 2280 CCA total, 12 Volt batteries will be for the truck engine.

• *A fourth group 31 battery with a minimum of 1000 Cold Cranking Amps shall be installed in the front lower compartment with a divider and access panel with four bolts and a battery isolator that will charge the battery from the chassis alternator. The wiring shall be insulated, and rubber grommets installed where it passes through the body. Special attention will be placed on the wiring for the AVL battery and the air ride cab so wiring is not damaged from the up and down cab movement. A circuit breaker will be added for safety to this system in the battery compartment. The extra battery only function will be to support the Automatic Vehicle Location System. The eight-gauge positive and negative wiring will terminate behind the passenger seat in the cab. The AVL battery compartment will have a plastic label that says in red “AVL battery only”. This battery compartment will be sealed vented and have a 12Volt fan. (Fan will run while vehicle is charging battery or shoreline connected.)*

• Air horn accommodation package, less horn

• All lighting to meet FMVSS

• 102 dBA back-up alarm

• A dash mounted 40 Amp dual output switch that controls one (1) remote power module outputs for high amperage loads such as a lightbar and emergency lighting

• Electrical system to be “Multi-plex” wiring and components

• Switch Panel:

• A minimum of six (6) lighted dash mounted switches with legends

• Wired “HOT” when the ignition switch is in the IGNITION/ON or ACCESSORY position

• The purpose and location of these switches shall be discussed at the pre-construction conference *Note: Center of dash.*

Any electronic device must comply with Part 15 of the FCC Rules. Operation is subject to the following conditions: Electronic devices may not cause harmful interference and must accept any interference received including interference that may cause undesired operation.

3.16 Engine

Must be a Cummins L-9 inline six (6) cylinder diesel, turbocharged with air-to-air

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Emergency Crew Transport Vehicle (ECT) inter-cooling, common rail fuel system, with a minimum of 350 hp, with 1050 foot pounds of torque (or equivalent to all listed requirements of the Cummins L-9) that meets all California Air Resources Board (CARB) emissions requirements for the State of California. The engine air intake shall be equipped with a one (1) stage, dry micronic air cleaner with safety element. The air cleaner intake (housing) shall be equipped with an OEM ember protection screen as per NFPA standards. The wire cloth specifications shall be as required in Section 6.8.

A full flow oil filter meeting the OEM engine manufacturer’s recommendation is required. All oil, fuel, and water filters will be easily accessible for maintenance. The engine governor shall be set at the manufacturer’s recommended governed speed.

The engines crankcase and oil pressure system shall be designed to provide full pressure lubrication when ascending or descending a 36% grade or traversing a side slope within manufacturer’s tolerances.

3.17 Auxiliary Braking

An auxiliary braking device that supplements the vehicle wheel braking system and provides the maximum vehicle hold back through the secondary braking system available for the specified engine/transmission combination shall be provided.

CAL FIRE prefers an OEM installed electronically controlled engine compression brake/exhaust brake combination with a two (2) position switch that can be turned OFF in either the LO or HI position (Ref. Jake Brake).

If a “Jake” style engine brake is not available, an OEM installed hydraulic output control for the Allison World Transmission, fully modulated, with a manually foot operated control and a dash mounted on-off switch shall be provided.

The auxiliary brake when activated shall operate in conjunction with the OEM stoplight system to enable stoplight function when the accelerator is suddenly released, and the secondary brake system is engaged (Ref. section CVC 24603 (f)).

3.18 Transmission

Shall be a fully automatic six (6) speed, Allison 3000 EVS for a two-wheel drive chassis or equivalent. A water to oil transmission cooler is required and shall be equipped with an electronic oil level indicator. The shift quadrant shall be a MULTI FUNCTION shift lever style control handle (if available). The transmission fluid shall be Allison’s “TranSynd” full synthetic oil (or equivalent Allison approved full synthetic). If the transmission is bid with a retarder, it shall include pricing and description of an OEM split cooler system for cooling of the retarder circuit separately of the transmission circuit (Allison option). Non-OEM external transmission coolers to meet this requirement are NOT ACCEPTABLE.

3.19 Cooling System

Shall be the manufacturer's maximum option available for the specified

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Emergency Crew Transport Vehicle (ECT) engine/transmission combination, thermostatically controlled with a pressure regulated overflow system, and a spin-on type coolant conditioner or 100,000 mile coolant. The system shall be designed to provide maximum cooling efficiency and circulation of coolant when ascending, descending, or parked (engine idling) on grades or side slopes within manufacturer’s suggested tolerances.

3.20 Fan Drive

Horton Drivemaster (or equivalent) with manual engage switch shall be installed.

3.21 Frame

• Shall be straight channel side rails. Stepped frames are not an option and will be rejected.

• Frame rails shall be heat treated alloy steel, Resistance Bending Moment (RBM) to be a minimum of 2,400,000 inch-pounds.

• 120,000 pound per square inch (psi) yield strength

• Two (2) frame mounted front tow hooks

3.22 Suspension

• Front springs: semi-elliptical or taper leaf with a total rated capacity at the ground equal to the maximum rating of the front axle

• Front and rear heavy-duty shock absorbers

• Rear springs: semi-elliptical with 4500 pound semi-elliptical auxiliary rear spring(s), total rated capacity at ground equal to the maximum rating of the rear axle. Auxiliary spring shall begin load bearing at a maximum of 2 inches of vertical travel of the main frame of the bare cab and chassis.

3.23 Wheels

Seven (7) each aluminum, ventilated, hub piloted, 10 holes, for flange nut installation aluminum single disc wheels shall be provided for each chassis. Rim size for the single fronts, dual rears, and a spare wheel shall be 22.5 X 8.25 rated for 11R22.5 tires. All wheels shall be interchangeable with each other. The wheel type and size must assure proper overall and compatible front and rear tread width.

3.24 Tires

Seven (7) each 11R22.5 load range "H" *each Michelin XDN2 or approved equivalent*, non-directional heavy-duty truck and bus, single front, dual rears and a spare tire shall be provided for each chassis. The tread design on the two-wheel drive chassis shall be highway tread on the front axle and Mud & Snow rated traction tread tires on the rear axle. [The spare tire and wheel must be the same brand and design as the front tires and shall be secured in the spare tire carrier (See Section 6.1 Spare Tire Carrier).] *Note: (3.23 and 3.24) Spare tire shall be shipped loose and secured in buildup to prevent movement or any damage to seats or interior of compartment.

Contractor shall be responsible for any damage to interior during shipping.*

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3.25 Fuel System

A 70 gallon minimum top draw aluminum tank shall be provided and mounted under the cab, or dual 50 gallon saddle tanks. The fuel filtration equipment shall meet the engine manufacturer's requirements. * The fuel tank straps will be covered with diamond plate aluminum 1/8-inch material* [Special Note: If dual saddles tanks are provided a heat shield shall be required for crossover fuel line under the exhaust pipe.] *Note: Single tank provided.*

*A ⅛-inch (minimum size) removable steel skid plate that is painted body or frame color shall be fastened to the bottom side of the fuel tank hangers on passenger side with minimum of four grade eight bolts and locknuts. The driver’s side of the truck will have a 1/8-inch (minimum size) skid plate that will cover the bottom of the exhaust fluid tank and air tanks. The bottom of both skid plates will have holes for gravel and debris to be washed out etc. The air tanks, battery box, and diesel exhaust fluid tanks will be covered in 1/8 diamond plate aluminum and be removable for servicing.*

3.26 Exhaust System

Shall be an OEM system, with a single frame mounted horizontal muffler. The tail pipe shall exit over the rear axle and shall be mounted to provide as much ground clearance as possible, but not any lower than OEM specifications.

The exhaust pipe shall not exit near any windows. Heat shielding/protection shall be provided as required to protect such items as fuel lines, speedometer cables, electrical wiring, brake hoses, compartment floors, batteries, fuel or water tanks and etc. from high exhaust heat. Any routing or modifications to the vehicle exhaust system or the addition of exhaust system materials or components must be OEM chassis manufacturer approved and in no way shall void any chassis manufacturer emission warranties.

The exhaust system requirements will be finalized at the pre- construction conference. *Note: Hangers to be provided every 12 inches and exit behind right passenger tire. The exhaust piping from exhaust filter to diffuser tip shall be made of all stainless steel. (flex, exhaust pipes and all clamps).*

3.27 Cab Paint

All cab and chassis painted surfaces except the cab roof shall be single color red, OEM automotive base coat/clear coat, (both sides) frame, axles, drive line, and bumper. The cab roof shall be painted white down to the drip rails or top of the door frames. Standard OEM finish on fuel tanks and OEM colored front bumper is acceptable. Aluminum Wheels shall not be painted.

Paint Reference Brand: Sikkens # 2303 Red; Sikkens # 4146 or 9219 White.

4.0 BODY REQUIREMENTS

4.1 General

All materials utilized shall be of open stock origin, commonly available through local sources for rapid and economical repair or modification of the body. The use of

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Emergency Crew Transport Vehicle (ECT) proprietary parts or materials in the construction of the body is unacceptable.

4.2 Exterior Dimensions *(See attachment AP-00-016568 ECT)*

• Overall length: Not to exceed 325 inches (including rear bumper)

• Overall body width: Not to exceed 98 inches (excluding rub rails and mirrors)

• Overall body height: Not to exceed 126.5 inches (unloaded)

• Minimum ground clearance: Shall be no less than 18 inches (fully loaded)

• Angle of approach: No less than 24° (fully loaded)

• Angle of departure: No less than [15-16°] *17* (fully loaded) *on rear buildup changes removal of spare tire 17.0*

4.3 Interior Dimensions

• Length: Forward wall to rear doors: Not to exceed 195 inches

• Width: Left wall to right wall: Not to exceed 95 inches

• Interior *floor*, to centerline of roof: Minimum 74 inches

4.4 Body Structure

The body shall be all aluminum and fully welded. Screw, bolts, rivets or other fasteners shall not be used for the attachment of any structural member or panel.

The main structure shall frame in the compartment openings and provide intermediate skin support. All grid structure tubing shall be welded together.

All material utilized shall be of the correct type, alloy, and thickness to withstand the intended usage and provide protection against cracking, corrosion, or metal fatigue.

The crew compartment body structural integrity shall meet the requirements of NFPA 1906, Section 10.4, which requires the body to withstand a force equal to 2.5 times the curb weight of the vehicle applied to the roof and the side of the vehicle.

Body frame members shall be tubular aluminum. All critical structural points shall be reinforced with gussets. Heavier gauge and larger dimension structural members shall be used where necessary to provide a safe and durable body construction.

Structural Integrity: The body shall be capable of providing impact, deformation and penetration resistance in the event of a collision. The body structure shall be capable of passing a stand-alone static load test on a type-tested body.

Inspection covers two on each side of the pass-through window of the heater and air conditioner module buildup will be provided to access the wiring and hoses in the front of the buildup. Each access cover shall be approximately 10 inches x 6 inches.

These covers shall be located inside the crew compartment. This system shall be finalized at the pre-construction conference. *Note: All body mounts shall have removable and inspectable covers for servicing as written. Inspection ports shall be on either side of the tool storage area on buildup in back wall against frame.*

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4.5 Rub Rail

Rub rails shall be bright finished/polished extruded aluminum or stainless-steel construction. The rub rails shall be at least 2.5 inches high x 0.75 inches wide and run along the lower edge of the body at the floor line, interrupted only by the wheel well opening. Rub rail will be *aluminum*.

4.6 Framing

The sidewall, end wall and roof framing shall be structural extruded aluminum tubing.

For strength the sidewall vertical posts and roof cross members are to be welded on all four (4) sides. The side wall, end wall, and roof structure members are to be spaced a maximum of 16 inches on center, except for the escape hatch framing which shall be wider to allow for the Transpec escape hatch.

The roofs shall form a crown along the center of the body or shall be flat as long as the design prevents water from pooling on the roof of the vehicle and the body meets the minimum interior dimensions. The interior roof framing in the forward section shall be flat for the mounting of the crew compartment air conditioning unit.

Roof shall utilize either a one (1) piece roof construction [or a two (2) piece roof formed module construction as described] *and* shall allow the wire harnesses to be routed without cutting the frame members and shall meet all specified test criteria.

One (1) Piece Roof Construction:

Perimeter Extrusions: A double hollow extrusion shall provide a structural transition between the module walls and the roof assembly.

Roof: The roof sheet shall be derived from one (1) piece. The four (4) edges of the sheet shall be continuously welded to the roof rail extrusion to prevent leaks. The roof sheet shall be supported by structural supports located at the load-bearing points of the module body. The roof structural support beams shall be spaced on a minimum 12 inches on center or as required for adequate load support.

[Two (2) Piece Roof Formed Module Construction:

Perimeter Structural Support: Formed module construction shall include a square tubing structure that shall provide required structural support for the roof and wall assembly.]

[Roof: The roof shall be constructed with a two (2) piece roof sheet, full seam welded to prevent leaks, with formed roof corners. The roof structural support beams shall be spaced on minimum 12 inches on center or as required for adequate load support.] Final frame, roof, siding, and wall skin to be finalized at pre-construction conference. *Note: 1 Piece Roof only.*

4.7 Exterior Roof Skin

The roof skin shall be [⅛] *3/16* inch formed aluminum full seam welded to the

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Emergency Crew Transport Vehicle (ECT) roof structure.

4.8 Drip Rail

An extruded, aluminum drip rail running full length at the top of both sides and rear of the crew body and over all exterior compartments above the rub rail shall be provided. Drip rails shall be installed with stainless steel screws and be detachable for easy replacement. All drip rails shall be finished with 45° angled ends to avoid hooking materials that brush against the vehicle.

4.9 Exterior Side Wall Skin

The sidewall skin on the body shall be [⅛] *3/16-inch* aluminum welded to the substructure. In addition to the welding a bond system shall be utilized full length on all wall and roof frame members. A polyurethane automotive grade adhesive sealant shall be applied to the edges of all structural tubing at the exterior wall surfaces. Due to occasional rear body damage, the rear main body skirt shall be a bolt on or riveted design. The rear facing corner posts shall be approximately 5 inches wide to facilitate the mounting of rear emergency lighting.

4.10 Body Seams

The body and panel joints shall be watertight and all openings between the chassis and occupant compartment shall be sealed.

4.11 Insulation

All walls, ceiling, floor and the entrance door shall be insulated to enhance the interior environment and to inhibit heat, cold and external noise from entering the crew compartment. The insulation shall be a non-settling polystyrene foam plank or foam sprayed material of maximum possible thickness depending upon location and available space.

4.12 Flooring

The sub floor for the body shall be ⅛ inch aluminum full seam welded to the cross and longitudinal sills. Welded to the sub floor sheeting, shall be aluminum tubing evenly spaced on minimum 12 inches on center to sandwich ridged foam board insulation between the sub floor and ⅛ inch non-skid aluminum diamond plate flooring.

The sub floor surface and the top of the wheel well tub shall be covered with non-skid ⅛ inch non-skid aluminum diamond plate. The aluminum shall be laid so that seams run parallel with the walls, with one (1) seam at each fender well. The floor seam layout shall be discussed at the pre-construction conference. *Note:

Welded as stated.*

The aluminum flooring shall cove up the sidewalls [approximately] *minimum* 3 inches to prevent water accessing beneath it.

4.13 Windows

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Six (6) crew windows shall be installed on the body, three (3) on each side adjacent to the crew seats, the approximate size shall be 19 inches high x 39 inches wide.

Lippert model # 5471-39 and #5472-39 or equivalent with aluminum frames with the darkest limo tinted glass shall be provided, add on tint is not acceptable. *The side windows will have a sliding screen for each window.*

All six (6) windows shall be flip-up emergency exit style windows with two (2) lift up emergency release levers on the inside of each crew compartment window frame.

A single, sliding camper style non-tinted window shall be installed on the forward wall of the crew compartment and shall be aligned with the sliding rear cab window of the particular truck chassis that is being supplied.

The rear entrance door shall have a tinted fixed window at interior eye height, approximate size to be 18 inches x 18 inches minimum (Safety Glass) mounted in rubber. All windows shall meet the requirements of (Federal Title) 49CFR 571 217 and (State Title) 13 CAC 1268 and 1269, whichever is more restrictive.

4.14 Privacy Screens

No privacy screens shall be mounted on any of the exterior buildup windows. Privacy screens shall be ordered as an option if required. See Privacy Screens requirements in Attachment 2E 4210-5617OPT.

4.15 Emergency Escape Hatch

A roof mounted low profile emergency escape hatch shall be installed (Transpec, Triple Value Safety Vent, 1070 series or equivalent).

4.16 Rear Crew Door

The door construction shall be ⅛ inch mill finish aluminum and use a heavy-duty polished stainless-steel continuous type hinge. The pin diameter shall be minimum ⅜ inch, staked at the bottom and the top with 1 inch maximum joint length. The rear center entrance door shall be double panel with a full height center hat section and installed flush fitting with the rear of the body. The interior door panel shall be removable to service door hardware.

The door shall be designed to be dust and weatherproof, utilizing recessed automotive closed cell door seals and be insulated. The approximate door size shall be 28 inches wide x 72 inches high. *The rear door shall not lock from the inside but will be lockable from the outside doorhandle. Note: All compartment doors shall be keyed the same to rear crew door. All compartment and door locks shall be keyed alike on each and all vehicles with the *exception of the rear door which shall be keyed alike with all other ECT’s*.

4.17 Wheel Wells

Shall be minimum [⅛] *1/4* inch. The wheel well to tire clearance shall be a minimum of 6 inches in a loaded condition to allow for installation of tire chains. A

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Emergency Crew Transport Vehicle (ECT) minimum [⅛] *1/4* inch plate shall be welded to wheel well and side rail interior to reinforce the area where side rail was cut for the wheel well.

4.18 Body Mounting

Particular attention should be directed to the method of body to chassis mounting.

Due to the severe loading requirements the entire unit shall be adequately reinforced to carry the required loads and withstand the rigors of stressed off-road operation.

The body shall not be bolted directly to the frame rails.

To provide the required amount of diagonal body flex, the body support system shall be designed, engineered and tested to reduce the natural flex stresses of the chassis being transferred to the body.

The body mounting system shall utilize a series of load carrying platforms that consist of a structural assembly that is attached to the passenger module understructure and is bolted to the outside of the chassis frame. Each body mounting location shall include a hard rubber isolation pad that is properly rated and matched to the passenger module operational weight.

All body mounting fasteners shall be a minimum of SAE Grade 8 *with 5/8 course bolts. The minimum body mount thickness for all body mount components will be 3/8 steel and will have no vertical bends or offsets for strength. These mounts will be reinforced and webbed together on all vertical and horizontal framing. The mounts will be completely welded to the subframe. The Springs that are used to allow the body to travel up and down will have a minimum travel of 7/8 inches on each mount after the spring is compressed with the mounting nuts. The body mount system will have provisions on each mount to keep the body continuously centered by vertical support tracks on all corners that allow the body to go up and down in a controlled track that will use stops on vertical bolts and springs. The minimum length for the body mounts will be six inches at the narrowest point of the system. The minimum width for the body mounts will be three inches at the narrowest point of the system. All rear body mounts will have access doors or openings to the mount for servicing. The above listed reference is the minimum body mount requirements that CAL FIRE will accept.* Body to frame mounting methods shall be finalized at the pre-construction conference. *Note: Final mounting agreed to as written.

Same mounts will be used on ECT’s as engines that will be made from 3/8 steel and have ¾ inch of travel for upload. The body mounts will have seven inch by seven inch inspection covers that can be removed for servicing that are attached with four bolts. *

4.19 Interior Body Fasteners

All interior compartment, lighting, seats, miscellaneous attachments, access covers, etc. will incorporate tamper proof fasteners such as pop rivets, anti-theft screws, etc.

5.0 COMPARTMENTS

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5.1 Compartment Dimensions

All compartment dimensions quoted are plus or minus 3 inches and are identified in the sections that follow. All compartments can vary in size within the tolerance but must meet the minimum volume requirements. All dimensions are given in inches in the form of Width X Height X Depth when facing the compartment opening. The final dimensions and configuration will be discussed at the pre-construction conference.

*See attached drawing AP-00-016568 Compartment*

5.1.1 Underbody

• Underbody L1: 45 x 18 x 21 inches AND 9 ft.3

• Underbody L2: 52 x 15 x 19 inches AND 8 ft.3

• Underbody R1: 20 x 18 x 21 inches AND 4 ft.3

• Underbody R2: 44 x 18 x 21 inches AND 9 ft.3

• Underbody R3: 20 x 18 x 21 inches AND 4 ft.3

• Underbody R4: 52 x 15 x 19 inches AND 8 ft.3

5.1.2 Exterior

• Exterior L1: 18 x 16 x 62 inches AND 10 ft.3

• Exterior L2: 18 x 16 x 34 inches AND 5 ft.3

• Exterior L5: 24 x 36 x 32 inches AND 15 ft.3

• Exterior L6: 32 x H* x 26 inches AND 35 ft.3

*H represents the interior height of the vehicle (74 inches minimum)

• Exterior R1: 18 x 16 x 31 inches AND 5 ft.3

• Exterior R2: 18 x 16 x 34 inches AND 5 ft.3

• Exterior R5: 24 x 36 x 32 inches AND 15 ft.3

• Exterior R6: 32 x H* x 26 inches AND 35 ft.3

*H represents the interior height of the vehicle (74 inches minimum)

5.1.3 Interior

• Interior 1-2: 24 x 36 x 32 inches AND 15 ft.3

(Sitting on top of L5 & R5)

• Interior L3-4: 18* x 16* x 34 inches AND 5* ft.3

*Wheel well may interfere with these dimensions on L3 & L4

• Interior R3-4: 18* x 16* x 34 inches AND 5* ft.3

*Wheel well may interfere with these dimensions on R3 & R4

5.1.4 Interior – Overhead Storage Compartments

• 6 compartments each: 39 x 15 x 24 inches AND 7.5 ft.3

See Attachment 2D (4210-5617DWR) for general layout drawings.

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5.2 General Construction

Interior and Exterior compartment shall have welded construction. All compartment walls and floors shall be fabricated from [1/8] *3/16* inch aluminum. Bolt together construction will be rejected. Access holes with cover panels shall be provided in compartments to allow access to body mounting bolts and spring pins, if necessary, to tighten or remove and install mounting bolts or pins. Brushed stainless-steel or aluminum diamond plate covers (scuff plates) shall be installed on all exterior compartment thresholds (lower door frames). The scuff plates shall extend below the lower door frames at least 1 inch to protect painted surfaces.

*All underbody compartments shall be removable bolt-on units that are fastened to the lower body structure cross sills with at least eight ½ fine thread grade eight bolts with locknuts, thick handwashers, and blue Loctite. The steel cage nuts shall be full length of tube and full width of frame to be connected at both sides, partial tube supports that are not full length will be rejected. A secondary hanger will be attached from box to buildup for additional support minimum width 2 inches.* These compartments shall be bolted to end and intermediate brackets that are welded to the compartment and the corresponding brackets that have been welded to the cross sills. Self-tapping bolts are not acceptable.

All interior and exterior compartment floors and shelves shall be fitted with removable Turtle Tile type material formed to cover the complete floor or shelf area. Two (2) minimum ¼ inch drain holes shall be installed in the underbody compartment floors.

All compartments except for the overhead storage compartments shall be sweep-out design with 360° air cell hollow compression door seals. Doorframes on compartments with sweep-out design shall have a flange to allow the installation of a knock-on type air cell hollow core, 360° compression door seal to create a watertight, dust free compartment.

Each underbody storage compartment shall be vented to the outside. All underbody compartments shall be vented with a 4 inch aluminum “Weber” style swivel vent with four (4) ¼ inch holes in the upper rear compartment wall (minimum dimensions). The swivel vent shall have a center bolt to lock the vent in either the open or closed position.

Vents shall be installed in such a way as to prevent water from entering the storage compartment. The final vent design shall be approved by CAL FIRE Representative during the pre-construction conference. *Note: Vents shall be installed as written with clarification to crew vent fan that will be ignition switch actuated.*

Anywhere in crew compartment that wiring is ran or electrical components protrude above the body interior skin surface whether through compartments or in bottom of top compartment shall be protected by an enclosed aluminum shield from gear damage or tampering.

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5.3 Compartment Door Construction

All compartment doors shall be fully enclosed double panel style with covered access to the compartment latch. Compartment doors shall be fabricated from 1/8 inch aluminum on the outer panels and orbital sanded, removable, 1/8 inch aluminum on the inner panels. Inner panels shall be fastened to the inner doorframe with security type Phillips or Torx head stainless-steel counter sunk machine screws.

*Compartment doors will be tack welded in four places so to not allow deflection and not be fastened by two-sided tape. Door jams hinges will be spot welded on at a minimum of six places or every six inches on a large door (four foot or larger) and not bolted or screwed.* Doors will not be accepted with washers or shims between buildup and door.

Compartment doors shall be designed to have a door opening as close to the dimensions of the compartment as possible. Compartment door openings over 26 inches wide (underbody compartments) may have two (2) doors with no center post.

Compartment doors shall be finalized during the pre-construction conference.

*Note: Door shall have the inner door panel either welded or bolted on. No epoxy or two-sided tape shall be acceptable on any doors.*

All compartment doors shall be flush fitting with a reinforced hat section. Unless otherwise specified, the compartment doors shall have polished, stainless-steel unpainted, continuous-type hinges, with a pin diameter of minimum ¼ inch and 1 inch joint length. Both rear tool compartment doors shall have polished, stainless-steel, continuous-type hinges with a pin diameter of minimum ⅜ inch and 1 inch joint length.

The compartment door hinges shall be mounted on the leading edges of all compartments except the double door compartments.

All compartment doors must be designed to ensure that no binding occurs while opening or closing when the vehicle is parked in flexed or twisted manner.

Special Note: Overhead Storage Compartments and Interior 1 and 2 doors shall be reinforced with a 1 inch x 1 inch square aluminum tube to eliminate warping.

5.4 Door Locks/Latches

Unless otherwise specified the compartment door latches shall be lockable, keyed alike, removable, flush mounted, polished stainless-steel, round cup style with retractable “D” ring handles, Eberhard # 9000-SSPL series with 206 slam lock (or equally rated, like-type latch system). Door latches shall be secured with stainless-steel Phillips head machine screws and lock nuts. Pop riveted latches shall be rejected.

The rear tool compartment doors shall have a lockable stainless-steel or chrome plated door handle compatible with a 3-point latch assembly (Austin # 107SS or equivalent).

The entrance door handle, lock and retention device shall meet FMVSS standard #

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206. The rear door lock will not be able to be locked from the inside only the outside of the door.

All enclosed latches shall have an interior removable cover if needed to prevent equipment from jamming the mechanism.

Dissimilar metal insulating gaskets shall be placed between the door handles and outer door panels to prevent any electrolytic reaction between dissimilar metals to protect painted surfaces. Rubber bumpers shall be installed on all surfaces where compartment doors may contact other doors or surfaces.

All compartment and door locks shall be keyed alike on each and all vehicles with the *exception of the rear door which shall be keyed alike with all other ECT’s*. [*Note:

All compartment door locks shall be keyed the same to rear crew door.*]

5.5 Door Checks

All vertically hinged doors shall have over center door stays located in the upper jamb area. Cleveland 2395 series double spring chrome plated door stays (or equivalent).

(Note: Rubber bumpers are acceptable only for the Exterior L2 and R2 compartments to allow maximum clearance for the tanks to be slid in/out of the compartment on slide-out trays.)

The crew compartment entrance door shall have an Eberhard socket type plunger #5602 (or equivalent) to hold the door in the open position on any road surface. The plunger shall be installed with a support backing and shall be located to provide clearance from other doors when the entrance door is in the open position.

Dissimilar metal insulating gaskets shall be placed between the door handles and outer door panels to prevent any electrolytic reaction between dissimilar metals and to protect painted surfaces. A 4 inch safety strap will be added to the *top and bottom* upper rear tool and crew doors to prevent them from going over 90 degrees. This will connect the door and the inside of the buildup. This will be finalized at pre-construction conference. *Note: Will meet spec as written.*

5.6 Compartment Shelves/Trays

All shelving or trays shall be manufactured from 3/16 inch brushed aluminum with at least a 2 inch vertical flange on all four (4) sides. The shelves shall be vertically adjustable, full height infinite, using a slotted uni-strut type track material. The minimum capacity rating for compartment shelving shall be 750 pounds and the shelf tracks shall be welded to the compartment walls. Shelves shall be located in both rear side interior and exterior side compartments R-5, L-5 and be 30 inches deep and

22.5 inches wide in each with a depth of 2 inches. These will also have adjustable tracks installed in all rear interior compartments and all rear side compartments R-5, L-5

5.7 Underbody Compartments

Four (4) additional sealed, fully removable compartment modules shall be fabricated

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Emergency Crew Transport Vehicle (ECT) and bolted to tabs welded to the floor cross sills to allow use of available storage space below the body floor. All underbody compartments shall be vertically hinged and open in the direction indicated in the attached drawing or opposite the handle shown in the drawing. The bottom underbody compartments will be attached with grade 8 ½ fine thread bolts and steel cage nuts and need to be the full length of the tube and full width made from ½ inch steel and bolted on with blue Loctite for retention.