Attachment_C_-_Bid_Specification_56816-041-211T.docx

56816-041-211

SPECIFICATION NUMBER: 56816-041-211

SPECIFICATION FOR: A MECHANICAL PICKUP, 4 CUBIC YARD CAPACITY, HIGH SIDE DUMP, BATTERY-ELECTRIC HIGHWAY SWEEPER- COMPLETE UNIT

PURCHASE ESTIMATE NUMBER: 32-12-6371

TECHNICAL SPECIFICATIONS

It is the intent of this specification to describe the minimum requirements for a PM10-compliant, battery electric, mechanical pickup highway sweeper with a four (4) cubic yard capacity high side dump hopper – complete unit.

The unit shall be the manufacturer's standard production model(s) and may only be modified to meet these specifications where specifically allowed. The unit may not be modified from its original configuration to meet the basic requirements of this specification. It shall be equipped with all the manufacturer's standard equipment and accessories which are part of the standard published literature

At its sole discretion, it is the State’s right to accept or decline any product offered as being equivalent to any referenced product in the Specifications or Drawings. Bidders should submit all documentation supporting their request to use alternative products or the referenced product may be denied.

Only technical changes authorized by DGS in writing will be accepted. Technical changes made by any other Division of Equipment, Caltrans or State employees will not be accepted in accordance with the IFB.

The unit shall comply with Caltrans Equipment Quality Standards for Electrical, Welding, Paint and Coatings as defined at:

https://dot.ca.gov/programs/equipment

This specification is composed of four (4) parts as follows: Chassis; Sweeping Unit/Sweeper; Complete Assembled Unit; and Administrative Requirements.

Bidders shall submit with bid, or within five (5) business days after request from the state, a weight study and layout of the highway sweeper ready to operate showing approximate location of major components (hopper, batteries, tanks, electric motors, cab, etc.). Layout shall include estimated weights for front and rear axle with hopper filled with 3.0 cubic yards of sand (7,000 lbs.), one operator at 225 lbs., and full water tanks.

DRAWINGS

The following Caltrans Division of Equipment drawings are part of these specifications:

CHASSIS

The basic chassis shall be battery electric with a purpose-built cab and operator’s station. The chassis shall be suitable for mounting a “highway sweeping unit” compliant with these specifications. In addition to these requirements, the chassis shall meet all requirements established by the manufacturer of the sweeper.

CAPACITY:

The manufacturer's Gross Vehicle Weight Rating (GVWR) shall not be less than 33,000 pounds; the actual manufacturer’s component ratings shall be as required by the sweeper manufacturer. The curb weight of the unit, complete with full capacities of water and lubricants, including the standard and specified equipment shall be as specified by the sweeper manufacturer.

WHEELBASE:

The wheelbase shall be as required by the manufacturer of the sweeper to insure proper loading and weight distribution of the complete assembled unit. The wheelbase shall be such that a minimum turning radius of not greater than 24 feet, measured at the outside of the tire, can be achieved.

MOTIVE POWER:

Motive power shall be electric with an electric motor with an electronic hour meter. The hour meter shall be displayed on the electric propulsion control panel (Ref. Hobbs Model 85006 solid state, or comparable).

FRAME:

The frame shall be as designed and required by the sweeper manufacturer to accommodate all sweeping equipment and components required for a specification-compliant unit.

COOLING SYSTEM:

There shall be two separate cooling systems. One cooling system shall include but not be limited to the electric propulsion system (i.e., electric motor, hydraulic motor, power electronics controllers, DC/DC converter, charger, etc.). The other cooling loop shall be dedicated to the high voltage battery systems. The two cooling systems may share the same reservoir. The cooling system shall be filled with a manufacturer suitable extended life anti-freeze. The change interval shall be the maximum possible as recommended by the electric motor, battery, and/or chassis manufacturer. The radiator shall be equipped with a deaeration system and temperature-controlled fan. A gauge shall be supplied and installed in the dash to measure coolant temperature.

The radiator shall be equipped with a low coolant level warning light in case the cooling liquid becomes low (Ref. Robertshaw Model 813 NLU or comparable). This warning light shall be mounted in the dashboard and in view of the driver.

All hoses used in the cooling system (including heater hoses and air compressor hoses) shall be Ethylene Propylene Diene Monomer (EPDM) hoses (or equivalent) with specified type hose clamps as recommended by the hose manufacturer.

ELECTRIC PROPULSION SYSTEM:

Sweeping and driving operations must be independent of one another. The electric drive shall be key operated start and stop system from operator’s cab. System shall include regenerative braking. Forward and reverse travel of sweeper shall be driven by electric motor. Other accessory items shall be as designed by sweeper manufacturer. System shall include the following at a minimum:

b. Electrical energy will be stored in a Li-Battery with 210kWh minimum capacity.

c. A 60 KW minimum motor to power hydraulics for the lifting of the elevator, pickup broom, and gutter brooms.

d. A liquid cooled 200 kW minimum motor to drive the vehicle.

e. Shall provide enough energy to accommodate 65 MPH travel speed and be water cooled.

f. Shall include an in-cab display for battery state of charge, temperature warning, and driving efficiency.

g. The system shall supply a battery service disconnect with fuse protection clearly labeled and accessible for emergency or servicing the system.

h. 8-hour continuous operation.

i. The design of the electric system shall meet all applicable safety standards and regulatory requirements. Documentation or labeling is required to acknowledge use, or disuse of any applicable safety standard, including but not limited to the applicable recommended practices in the latest version of SAE J2910 Recommended Practices for the Design and Test of Hybrid Electric and Electric Trucks and Buses for Electrical Safety.

CHARGING:

The following charging capabilities and charger shall be included:

j. The sweeper shall come equipped with a 20kW onboard charger with industry standard charging connector(s) that conforms to SAE protocol J1772 (proprietary charging connectors or cables shall be rejected).

k. The sweeper’s battery charging system shall be capable of accepting an electrical charging rate of a minimum of 200 KW from DC fast charging electric vehicle supply equipment. This will include installing a fast charger interface board and an SAE J1772 DC CCS connector port.

l. Level 2 electric vehicle charging equipment shall be supplied and be compatible with SAE J1772 compliant vehicles. It shall supply 208/240 Voltage on a 100 Amp branch circuit (80 continuous Amps). The station shall be fully sealed to NEMA 4 (or comparable) and suitable for indoor/outdoor use, be pedestal mounted, be plugged into a standard 220V outlet, and have a retractable cable management system. The charging cable shall be a minimum of 25 ft.

Delivery locations of this item will match those vehicle delivery locations on the purchase order. Inspection, delivery, and final acceptance of all units on the Purchase Order shall be within 90 calendar days after the Purchase Order date. Contact the State of California, Department of Transportation, Division of Equipment, Equipment Parts Coordinator listed on the PO contact sheet to coordinate delivery.

Acceptance of delivery or placement in operation of any equipment shall not release the manufacturer from liability for faulty design, workmanship, or materials appearing even after final payment has been made.

NOTE: Delivery time for this item is different than the specified vehicle.

MAIN CONTROL UNIT FOR ELECTRIC PROPULSION SYSTEM:

The sweeper shall provide sweeping speeds at 1 MPH, up to 12 MPH and be capable of traveling at highway speeds of not less than 65 MPH on level ground (0.5% grade) when fully loaded. The unit shall monitor electric motor usage and control the motors operational speed rates.

FRONT AXLE:

The Gross Axle Weight Rating (GAWR) of the front axle, springs, brakes, wheels, and tires shall be as specified by the sweeper manufacturer. The axle and component manufacturer’s actual ratings shall not be less than 12,000 pounds.

The bearings shall be lubricated by an oil bath, and the hubs shall have Stemco type oil seals with a transparent cap to view the oil level. The lubricant shall be the synthetic type (Ref. Emgard 50W, or as recommended). The hubs shall be labeled to indicate they have been filled with a synthetic lubricant.

REAR AXLE:

The rear axle shall be equipped with a two (2) speed differential to provide for reduced sweeping speeds while maintaining high electric motor RPM. This speed reduction unit shall be equipped with a safety device to protect against low range engagement while the vehicle is in motion. The axle manufacturer’s actual rating may be more than the GAWR.

The gear ratio supplied shall provide a maximum speed of not less than 65 MPH. The hubs shall have oil lubricated wheel bearings and an oil seal (Ref. Stemco Guardian Hub Seal or comparable).

The rear axle differential shall be filled with a synthetic type gear lubricant (Ref. Emgard 75W-90, or comparable). The fill location(s) shall be labeled to indicate the differential has been filled with a synthetic lubricant.

FRONT SUSPENSION:

The suspension of the front axle shall be leaf springs with heavy duty shock absorbers and shall have a rated capacity of not less than the GAWR of the front axle.

REAR SUSPENSION:

Rear suspension may be leaf springs, air suspension-type, or rubber cushion (i.e., Chalmers) type; and shall have rated capacity no less than GAWR of rear axle. Rear shock absorbers shall be provided if air suspension is supplied.

BRAKES:

The sweeper shall be equipped with service, emergency, and parking brake systems as follows:

m. Service Brakes: The service brakes shall be self-adjusting disk brakes on all axles to match the axle load rating. The brake system shall be in compliance with all Federal Motor Vehicle Safety Standards (FMVSS). Service brake for front and rear wheels shall be power-assisted hydraulic brakes which may be equipped with either a vacuum, air, or hydraulic type booster system.

n. Emergency Braking: An emergency (auxiliary) braking system shall be installed to allow the operator to stop the machine in the event of any failure in the service braking system. On hydraulic brake systems, a red warning light shall be installed on the instrument panel, in full view of the operator, to indicate when the emergency braking system has been activated.

o. Parking Brake: A parking brake shall be installed and may be connected to the service brakes or operated independently on the drive shaft or transmission output shaft. On hydraulic brake systems a red warning light shall be installed on the instrument panel, in full view of the operator, to indicate when the parking brake is applied while the electric propulsion system is running.

The service brakes, emergency brakes, and parking brake shall conform with the braking performance requirements as established by the Federal Motor Vehicle Safety Standards (FMVSS) and the California Vehicle Code (CVC) for the vehicle being supplied.

STEERING GEAR:

The sweeper shall employ front wheel steering, controlled by a steering wheel(s) with hydraulic power assist. The steering wheel(s)/column(s) shall have tilt (minimum) and telescopic capability (where available) to accommodate the ergonomic requirements of different size operators.

TIRES AND WHEELS:

The sweeper shall be equipped with tubeless, radial truck tires and wheels with load ratings that meet the vehicle's front and rear Gross Axle Weight Ratings (GAWR); the sweeper’s Gross Vehicle Weight Rating; and, as required by the sweeper manufacturer. All tires shall have a highway-type tread. Tires shall be mounted on drop center, hub-piloted wheels with a minimum two (2) hand holes each for dual wheels; and, if available in the required size for single wheels.

All wheels shall meet or exceed their corresponding maximum tire load and inflation ratings and be labeled to identify its maximum load and inflation ratings. Dual wheels shall be mounted using two-piece flange nuts. All tires and wheels supplied on each axle shall be the same make and model (front and rear wheels may differ in model), mounted and balanced as an assembly.

Wheels shall be surfaced finished in white, gray, black, or brushed alloy.

The use of spacers between the wheels or the wheel and the drum or hub are unacceptable.

CAB/OPERATOR'S COMPARTMENT:

A fully enclosed, insulated, and weatherproof operator's compartment shall be provided, and, in general, shall provide maximum operator protection and comfort. The cab shall be a purpose-built centrally located cab with one (1) operator’s position. The operator's compartment must be equipped with an additional jump seat (for training purposes) to allow two people to ride in the cab during sweeper operation. This additional jump seat shall be equipped with a backrest and seat belt with an emergency locking retractor.

The cab shall be equipped with, but not limited to, the following items:

p. Safety glass windshield and tempered glass windows.

q. Headliner and floor mats.

r. Key-type locking door(s) with four sets of keys.

s. Fully adjustable, fully padded, cloth, air suspension type, high back bucket seat(s) with lumbar support, armrests and three (3) point seat belt(s).

t. A tinted front windshield with heavy duty, 2-speed (w/ intermittent) windshield wiper(s) with washer(s), interior sun visor(s), and a defroster.

u. A recirculating-type heater with an adjustable temperature control.

v. Manufacturer’s standard AM/FM radio with Blue Tooth capability (if available), complete with speaker(s) and antenna.

w. Gauges: All necessary gauges including, but not limited to, speedometer, odometer, coolant, air pressure, battery state of charge, 12V battery voltage, and all those required in these specifications, supplied and installed in view of the operator.

x. All gauges shall be permanently labeled to identify their functions with a simple and readable lettering style or equivalent international symbols. All gauges shall be back-lighted or illuminated for nighttime operation.

y. Warning Devices: All necessary warning devices required in these specifications shall have their own source for actuation, rather than being dependent on another visual instrument, such as a thermometer or gauge. Warning lights shall be bright and located forward of the operator. Audible alarms shall be distinguishable from the operating noises of the vehicle.

NOTE: A gauge is not an acceptable visual warning device unless it is accompanied by a red light which illuminates or flashes upon reaching a critical condition.

z. Mirrors: Right side and left side, electrically heated and adjustable, exterior side-view mirrors, not less than 90 square inches, shall be installed. Both mirrors shall be electrically adjustable from each operating station. The mirrors and mounting brackets shall be OEM factory-installed breakaway type; black, gray or neutral in color. Alternately, mirrors may be mounted in a stainless-steel case with a ratchet type, stainless steel, retractable bracket (Ref. Re-Trac Universal Model 1572).

aa. In addition to the cab-mounted OEM mirrors previously described, a 10-inch (minimum) round convex mirror shall be mounted just below the primary mirrors on each side for gutter broom viewing. In addition, an 8-inch (approximate) diameter convex mirror shall be mounted just above the primary mirrors on each side for increased rearward visibility.

ab. Halogen headlamps, or better.

ac. Dome light. Light shall be activated by opening the driver door, the passenger door (if so equipped), and by a switch in the cab.

ad. Air Conditioning: An air conditioning system shall be installed with adequate capacity to reduce the operator environment temperature a minimum of 20oF below the ambient for ambient temperatures between 85oF and the highest ambient temperature at which the machine is designed to operate. The air conditioning system should not allow the operator environment humidity to exceed 70%. The use of R12 refrigerant will not be acceptable. The system shall include fresh air ventilation.

ae. Storage Compartment: A means for storing or securing within the operators compartment small items such as hand tools or operator’s personal effects shall be provided.

af. Hand rails and steps for safely entering and exiting the cab.

ag. 12-Volt Power port(s) - (i.e., Cigar lighter-type and/or USB).

ah. Dedicated (“clean”) fused power leads, 20-amp, 12-volt positive and negative, and ignition feed shall be provided to the cab for a two (2)-way mobile radio(s). This wiring may be an OEM factory option (preferred) or dealer installed. The two (2)-way communication radio(s) will be installed by Caltrans personnel.

ai. Horn.

CONTROLS:

Operator’s station shall be equipped with hand and foot controls conveniently located to provide the operator maximum comfort during operation. All controls shall be permanently labeled to identify their functions with a simple and readable lettering style or equivalent international symbols.

A single operator control station shall be centrally located on the vehicle and the cab is reduced in size to provide the operator direct visual contact with both the left and right side gutter brooms while sitting in the operator's seat.

12 VOLT ELECTRICAL EQUIPMENT:

Minimum electrical equipment shall comply with all Federal Motor Vehicle Safety Standards and State of California Department of Motor Vehicle regulations. The tail, stop, and directional signal lamps may be in combination, and the wires to these lamps shall be in a loom or conduit. The battery system shall be made up of 12‑volt accessible maintenance free battery or (batteries). The system rating shall be as specified by the electric propulsion system manufacturer or sweeper manufacturer. Side terminal batteries are not acceptable. NOTE: Battery (box) location shall be as required by the sweeper manufacturer. The systems shall be recharged through the vehicles lithium-ion battery charging process.

Resettable circuit breakers shall be supplied in lieu of fuses, where available.

PAINT – CAB AND CHASSIS:

The cab, hood, and fenders shall be finish painted with lead-free Winter White (or equivalent) color. The finish coat shall be free from runs, drips, sags, etc., and shall be evenly applied to provide a gloss finish.

The finish or top coat shall be compatible for re-coat or touch-up with lead-free,

- Axalta Imron Elite Productive, EX, Polyurethane Enamel

- PPG Delfleet Evolution, FDSU, Ultra High Solids Polyurethane

- PPG Delfleet Evolution, FDGU, Ultra High Solids Polyurethane Enamel

- Sherwin Williams Genesis, GC, [G]LV, [Single Stage] Acrylic Polyurethane, Fleet White or equivalent color. Other components may be finished according to the factory standard finish.

Optionally, the unit may be finished by powder coating. The powder coating shall be lead free (300 PPM LEAD MAX) and of a matching color to that specified above (Fleet White). Proper material preparation, application, and curing, as recommended by the powder coating manufacturer, shall be complied with. Color match of the proposed powder coating shall be approved by the Specifications Engineer prior to production.

MISCELLANEOUS:

The following equipment shall be furnished and installed:

aj. Standard front bumper.

ak. Tow hook(s) or pin(s) mounted on the front for towing the vehicle empty.

al. All filters, where applicable and available, shall be the spin‑on type.

SWEEPING UNIT / SWEEPER

GENERAL DESCRIPTION:

It is the intent of this specification section to describe the minimum requirements for a PM10-compliant, battery-electric, mechanical pickup highway sweeper with a four (4) cubic yard capacity high side dump hopper. The sweeper shall be certified PM10 compliant in accordance with Rule 1186 of the California South Coast Air Quality Management District (SCAQMD) prior to Purchase Order award.

In addition to typical street sweeping speeds, the sweeper shall be able to travel at freeway speeds up to 65 MPH. The sweeper shall be designed and equipped to sweep and travel at ambient temperatures of 110º F, and to operate as specified at all elevations from sea level to 8,500 feet above sea level.

The term "sweeping unit" shall refer to the assembly of components built by the sweeper manufacturer and designed to pick up and store roadside debris. The term “purpose-built chassis” shall refer to the sweeper manufacturer's cab and chassis on which the sweeping unit is mounted. The term "sweeper" shall refer to the entire vehicle including both the sweeping unit and the purpose-built chassis.

WEIGHT:

The empty weight of the base sweeper - with standard equipment, operator, and full tanks, lubricating, cooling, hydraulic, and water systems, shall be such as to provide maximum payload capacity while not exceeding any front or rear axle ratings, or the gross vehicle weight rating (GVWR) of the unit.

With full water tank(s) full, and an operator, the unit shall comply with the weights allowed by the California Vehicle Code (CVC) for 2-axle vehicles.

When fully loaded with debris as would occur in a normal sweeping operation (hopper full, water tanks(s) empty), the Gross Axle Weight Rating (GAWR) of the front and rear axles shall not be exceeded. Also, in this condition of loading, the weights allowed by the California Vehicle Code (CVC) or California Bridge Law(s) for 2-axle vehicles shall not be exceeded. The manufacturer's Gross Vehicle Weight Rating (GVWR) shall not be less than 33,000 lbs.

HYDRAULICS:

Hydraulic system shall be equipped as follows:

am. Cooling: The hydraulic oil should not exceed 180 degrees Fahrenheit (F) at maximum at 110 degrees F ambient temperature.

an. Tank: A hydraulic oil reservoir shall be supplied and be equipped with an oil level sight gauge.

ao. Relief Valves: The hydraulic system shall be equipped with relief valves located in each implement circuit to protect all hydraulic components.

ap. Filtration: A spin-on (preferred) or cartridge type, return filter with bypass valve to prevent the restriction of flow in the event that the filter becomes blocked shall be supplied and installed on all hydraulic system(s). The filter head shall have a filter condition indicator installed to indicate when the filter needs to be changed.

The filter assembly shall be installed convenient to the operator when changing the filter element.

aq. Ball type, shut-off valves shall be installed between the pump and strainer (if a strainer is supplied) and above (before) the return filter if the filter cannot be removed without draining some or all of the hydraulic system.

ar. Material: All hydraulic hoses shall be crimp type, high pressure hoses with corresponding fittings. No galvanized or black iron fittings will be allowed.

as. Auxiliary Ports: If the hopper assembly must be raised to access and perform emergency repairs on the hydraulic power source, two (2) auxiliary hydraulic ports shall be provided to allow an external hydraulic power source to actuate the hopper lift circuit.

at. Gauges: Hydraulic oil temperature gauge(s) for the sweeper systems (and drive system, if hydrostatic) shall be supplied and installed in the dash.

au. Warning Devices: Visual and auditory warning device(s) for high hydraulic oil temperature shall be installed and set according to device manufacturer.

av. Sampling Port: Sweeper shall be equipped with hydraulic fluid sampling port on hydraulic oil return line to allow operator to draw from system, hydraulic oil samples for oil analysis. Oil sampling port shall be ball type valve with pipe plug or cap installed on discharge.

HOPPER ASSEMBLY:

Hopper assembly shall meet all performance requirements. Hopper functions shall be powered. Hopper shall provide low and high, side-dumping, and be equipped as follows:

aw. Volume: A minimum payload volume (volumetric) capacity of four (4) cubic yards of material.

ax. Interior Coating: A light colored, smoothly finished, polyurethane-type (or comparable, e.g., Line-X, etc.) interior coating to help resist hopper corrosion and facilitate a more efficient hopper clean out.

ay. Support Device: A support device (body prop) to prevent accidental lowering of the hopper when in the elevated (dumping) position for maintenance and servicing purposes. The safety support may be the automatic engage/disengage type; or, the manually installed type.

az. Indicator System: A hopper "FULL" indicator system which shall indicate only when the hopper has reached its maximum capacity. The indicator light shall be visible to the operator during normal operation.

ba. Hopper Lift Capacity: A lift capacity of 12,000 lbs. to maximum dump height, and a minimum dump height of 108 inches at a 45o dump angle shall be provided.

bb. Dump Control: The hopper dump control shall be located convenient to the operator’s station and properly identified.

GUTTER BROOM ASSEMBLIES:

Gutter broom assembly shall meet all performance requirements. Gutter broom functions shall be powered and fully operational from within the cab. Brooms shall operate individually or simultaneously, provide for at least a 10-foot sweeping width (in conjunction with the pickup broom), and provide for no more than 102-inch vehicle transport width.

Gutter broom assemblies shall have a minimum 42-inch diameter; multi-segment, replaceable brushes; a guard or other means to protect the gutter broom's drive shaft from material wrap-up; and, a tilt and down pressure adjustment controlled by the operator in the cab.

The gutter brooms shall cease rotating when in the fully lifted position and shall resume rotating when the lowering sequence is complete. The gutter brooms shall not be stationary when in the fully lowered position with the vehicle moving forward at travel speed. Alternately, an audible or visual warning that the gutter brooms are down and not rotating is acceptable.

MAIN PICKUP BROOM ASSEMBLY:

Main pickup broom assembly shall meet all performance requirements. Pickup broom functions shall be powered and fully operational from within the cab. Broom shall be at least 48-inch-long by 32-inch diameter; and be equipped with tilt and wear pressure suspension adjustments.

CONVEYOR ASSEMBLY:

Conveyor assembly shall meet all performance requirements. Conveyor functions shall be powered and fully operational from within the cab; and be capable of filling hopper with at least four (4) cubic yards of sand, bottles, cans, rubber tire segments, or other debris encountered on highway shoulders and flicked up by pickup broom.

The conveyor assembly shall be equipped with the following:

bc. Shielding: Any shielding necessary to prevent debris from interfering with normal conveyor operation.

bd. Warning Device: A cab-mounted, stall warning light to notify the operator when any portion of the conveyor assembly has stalled including any driven or non-driven component of the conveyor system.

WATER SPRAY SYSTEM:

Sweeper shall have full sweeping width water spray system that is certified PM10 compliant in accordance with South Coast Air Quality Management District (SCAQMD) Rule 1186, operational from within the cab, and equipped with the following:

be. Tank(s): Tank(s) capacity shall be not less than 250 gallons and be fabricated from rust-free type material. Water capacity shall be such that sweeping time under PM10 compliance conditions shall be maximized.

The tank(s) shall have the following:

i. Drain Plug(s): Drain plug(s) with a minimum 6.0-inch ground clearance and located at the bottom or within 1.0 inch of the bottom of each tank shall be provided. Drain plugs shall be protected.

ii. Fire Hydrant Fill Inlet: A fill inlet for filling the tank(s) from a fire hydrant shall be provided. A back-flow prevention system conforming to the drinking water supply requirements in the California Administrative Code, Title 17 "Public Health" shall be provided.

iii. 3/4-inch Hose Fill Capability: A means to fill the tank(s) with a standard 3/4-inch garden hose unattended by the operator shall be supplied. A back-flow prevention system conforming to the drinking water supply requirements in the California Administrative Code, Title 17 "Public Health" shall be provided.

iv. Gauge: A dash mounted, water level gauge shall be provided and visible to the operator at all times during sweeping operations.

bf. Pump: The water spray system shall be equipped with an electric driven water pump, of the proper size and type to supply the necessary pressure and volume of water to the spray bars/jets. A centrifugal water pump shall be protected by a low water safety device which will automatically disengage the pump drive if little or no water is present at the suction port. The water pump shall be protected by an in-line, cleanable strainer with a clear (if available) polycarbonate housing for visual check of strainer.

bg. Hoses: The sweeper shall be supplied with the following hoses:

v. A minimum 25-foot-long filling hose capable of coupling to a 2.5-inch NST fire hydrant outlet. The filling hose shall be fabricated of 100% polyester with hypalon impregnation and shall be “industry-standard” rated for working pressure and burst strength.

vi. A minimum 50-foot-long, 3/4-inch, nylon reinforced garden hose.

bh. Valves: All water control systems shall use ball or butterfly type valves for quick open and close applications. Gate valves are not acceptable.

bi. Front Spray Bar: In addition to water spray system required for PM10 compliance, a full-width spray bar shall be provided at the front of the sweeper. This spray bar shall operate independently from PM10 water spray requirements, and shall be adjustable from operator’s compartment, from fully closed to fully open. Nozzle size and placement shall be sufficient to control excessive dust generated by the material being swept.

AUTOMATIC LUBRICATION SYSTEM:

Sweeper shall be equipped with automatic, grease type, lubricating system. Automatic lubrication system (auto lube) shall be installed to ensure proper lubrication of sweeper components, including: all cylinder and hinge pins, shafts, bearings, linkages, and any other components except u-joints that require regular greasing as instructed in the operator’s manual of the sweeper manufacturer. Automatic lubrication system shall be compatible with NLGI #2 grease (Ref: Chevron Ultra-duty or equivalent), and use one centralized distribution point (Ref: Midwest Autolube, Lincoln QuickLub, or equivalent). Grease reservoir shall be equipped with top follower plate and seal that visually shows grease level.

1. LABELING:

Controls, instrumentation, and service points shall be permanently labeled. Labeling shall be as follows,

bj. Labeling shall be in English and standard US units or equivalent international symbol, clearly and readily identifiable.

bk. Labeling shall be machine produced permanent – etched, engraved, machined, or printed with contrasting background.

bl. Attached labels shall be metal or UV resistant plastic secured with hardware (NOTE: Adhesive type decals may be acceptable with prior approval from engineer).

Service point labels shall describe daily and periodic lubrication and service instructions including product type.

ACCESS:

The sweeper shall provide quick and easy access to all operational check points and all replaceable filters normally encountered by the operator or service mechanic when maintaining or servicing the sweeper in accordance with the manufacturer's published instructions. Where needed for convenience and cleanliness, remote mounted filters, fill ports, drain ports (i.e., remote oil drain valve), and dipsticks shall be provided and installed.

Any special tools required for routine inspection, adjustments, or preventative maintenance shall be provided for each sweeper.

Doors, large access panels, etc., shall be provided with a means of being secured in the open position. This shall be provided to protect against inadvertent closing due to wind gusts, parking on uneven ground, etc.

The sweeper shall also be equipped with adequate steps, railings and handles located on each side of the unit if routine conveyor inspections and adjustments are required by the manufacturer. Steps shall be positioned low enough for easy mounting if required for daily pre-op inspections.

Labels shall be installed in conspicuous locations near the service point(s) that describes the operator’s daily and periodic lubrication and service instructions, including product type. These labels may be comprehensive in nature.

MISCELLANEOUS:

Miscellaneous components to be supplied and installed shall include, but not be limited to, the following:

bm. A fire hydrant wrench.

bn. Storage Compartment: The sweeper shall be equipped with a storage compartment to store the water filling hoses, hydrant wrench, and other hardware supplied with the sweeper.

bo. Stability: With a full hopper, the sweeper shall be capable of maintaining vehicle stability on the highway shoulder under all dump-cycle operations.

bp. Special tools required for inspection, adjustments, or preventive maintenance shall be provided with each sweeper.

bq. Front Mount Basket: Supplier shall fabricate and install basket shown on Drawing Numbers L2-D002-01 and –02. Punched or precision-cut metal may be used in lieu of expanded metal. Basket ground clearance shall be at least 24 inches.

br. Wheel Spray/Splash/Stone Throw Protection: Sweeper shall be equipped with mud flaps and fenders as required to comply with CVC Section 27600. Rear mud flaps shall be anti-sail type.

COMPLETE ASSEMBLED UNIT

Complete unit shall be delivered fully assembled, ready to operate. Sweeper manufacturer shall obtain an executive order certifying its sale into California by the California Air Resources Board New Vehicle and Engine Programs Branch. The sweeper and all furnished components shall be compatible to maintain the integrity of the entire assembly. There shall be provisions to secure all loose components on the vehicle for transit.

MOUNTING:

The sweeping unit and all requested options and attachments shall be mounted by the supplier on a current model described herein.

The sweeping unit shall be mounted per manufacturer’s recommendation.

LINKAGE SYSTEMS:

All component linkage and actuation systems not specifically covered in the specifications shall be required to accurately operate the component according to the component manufacturer's specifications. These systems must maintain their designed configuration, adjustment, and serviceability through repeated cycling.

HYDRAULIC LINES AND FITTING:

All hydraulic lines shall be sized as recommended by the manufacturer of the component to which they attach and shall be adequate for the use intended. All hoses and plumbing shall have a minimum number of bends and shall be free of any kinks. All bends in hoses and tubing shall be not less than the minimum radius as recommended by the hose or tubing manufacturer. Where applicable, plumbing shall be protected from external damage by truck frame and body. Any hoses routed around or through areas that may cause abrasion or cuts shall be protected as necessary. All hydraulic components and plumbing shall be mounted and supported to withstand extensive field use.

Any tubing or flexible hose used in the hydraulic system shall be approved for hydraulic use and rated for the maximum working pressure of the system. Large diameter hose shall be used for low pressure return line(s) to the reservoir. The use of black iron pipe, galvanized pipe or plastic pipe or fittings, etc. shall not be allowed in the hydraulic system, including the suction or low pressure return side. Brass ball valves and fittings may be used in the low-pressure side of the system only. Steel pipe fittings welded into hydraulic tanks are acceptable. Only steel or stainless-steel crimp type hose fittings and ends which are approved for hydraulic use shall be used (Aeroquip or equivalent).

Hydraulic fittings on high pressure lines shall be the swivel type, steel or stainless steel, and shall be 37o JIC, NPT, SAE "O" Ring Boss, or SAE "O" Ring Flange. Fittings shall be of the proper size to match the hydraulic line to which they attach. No welding of fittings will be allowed. Compression type fittings shall not be used in the system. All threads shall be North American or Japanese Metric type threads. NOTE: Thread types shall not be mixed on the unit (i.e., thread types shall be all American or all Metric). A hydraulic filter shall be supplied in a pressurized hydraulic system that meets or exceeds the filtering requirements of all components in the system.

CONTROLS:

All controls - electrical, mechanical, pneumatic, hydraulic, etc. shall be within easy access to the operator. Steps and grab handles shall be provided where necessary to provide safe access to controls. Controls shall be appropriately labeled for their function. All labels shall be fabricated from metal or plastic and mounted with rivets or screws (NOTE: Adhesive type decals are not acceptable without prior consent from Department of Transportation, Division of Equipment, Specifications Engineer). Lettering on labels shall be easily readable, shall be etched, engraved, or machined and shall contrast with the label color. All labels and gauges shall be printed or marked in English and standard U.S. units.

Any gauges and instruments required to operate the unit shall be visible to the operator, at or near the controls being operated. All gauges shall be permanently labeled to identify their functions with a simple and readable lettering style or equivalent international symbols. All gauges shall be panel mounted, shall be consistent in size, color scheme, pointer design, label style and size. All gauges and instrumentation shall be adequately illuminated for nighttime operation. All external gauges, switches, and controls shall be weather proof and rated for external usage.

MATERIAL:

Construction shall be of all new material free of rust and any defects. All components in the assembly shall be fabricated from a single piece of material. Material which is joined by welding or other means to form a single piece of stock is not acceptable. The finished product shall be free of dents and warpage. The use of any type of body filler is unacceptable. All bolts shall be Grade 5 or better and conform to SAE and ASTM standards. Bolt lengths shall be such that a minimum of two threads shall extend beyond the nut. Nuts shall be the locking type. Nuts and washers shall be compatible with the bolt(s) to which they are attached, as recommended by the fastener manufacturer and in accordance with SAE and ASTM standards. If requested, the supplier shall submit proof of fastener strengths.

WELDING:

All welding shall comply with the requirements as represented in American Welding Society (AWS), D14.3 2019, and American National Standard entitled "Specification for Welding Earthmoving and Construction Equipment."

All welds shall be continuous except as noted. Intermittent or spot welds shall be spaced and proportioned to provide ample strength for the material being welded. Weld sizes not indicated shall be equal to the thickness of the least of the joined plates.

All welds shall be properly fused, displaying proper penetration and a professional finish, and must meet the qualification requirements of applicable AWS specifications. Examples of unacceptable weldments are:

a. Cracks d. Excessive Splatter

b. Undercut e. Blow Holes

c. Overlap f. Slag Entrapment

Any weld failing to comply with the AWS specification or failing to pass a quality assurance inspection performed by the State, will be corrected by the manufacturer, at their expense, and be corrected off State property. The State shall determine if a weld is acceptable or deficient.

Any deficient weld shall be corrected by a welder who is certified in accordance with the requirements as established by the American Welding Society (AWS). The welder shall have the proper certification documents indicating that he/she is qualified to perform the type, size, and position of the weld performed, with the welding process utilized, and on the material being welded. The supplier will be required to supply proof of current welding certifications for personnel performing any re-welding on the unit, upon request of the State whether written or verbal.

GRINDING OF WELDS must have prior approval of the Department of Transportation, Division of Equipment, Engineering Specifications. Welds which have been ground without approval shall be subject to complete re-welding upon request, at no additional cost to the State.

All assembly dimensions and tolerances on drawings apply after welding. Excessive warpage of assembled parts is not acceptable. Weld symbols on drawings shall be interpreted per American National Standard Welding Symbols. In the event of the lack of a weld symbol, the best commercial practice shall prevail. The covering of welds with body fillers or similar materials is unacceptable.

METAL SHAPING:

All breaks shall be free of cracks. Radii shall be at least twice the thickness of the material or in accordance with the requirements established by ASTM for the particular material being formed, whichever is greater. All holes shall be round, of the proper dimension, perpendicular to the material they are produced in, and finished smooth. Oblong holes or holes drilled, bored, etc. at angles are not acceptable. Holes and slots shall be drilled, punched, saw cut, plasma cut, or milled; torch cut is unacceptable. Sharp edges and corners on all material shall be radiused to prevent personnel injury. This includes expanded metal.

ELECTRICAL EQUIPMENT:

Minimum electrical equipment shall comply with all Federal Motor Vehicle Safety Standards (FMVSS) and State of California Department of Motor Vehicle regulations. Notwithstanding any Federal or State minimum requirements, each unit shall be equipped with two (2) taillights, two (2) stop lights, and turn (left and right) signals. All lights shall be light emitting diode (LED) recessed type, mounted in rubber grommets. The tail, stop, and turn signal lamps may be in combination (Ref. Truck‑Lite #44982R (round); #60885 (oval); with ‘hard coated’ lens; or comparable). Backup lights shall be installed (Ref. Truck‑Lite 44141C, with ‘hard coated lens; or comparable). Grommets shall match the light used. Side marker, clearance, and ICC lamps shall be 2½-inch LED units (Ref. Truck‑Lite #10250R, #10250Y and #10700 grommets; or comparable). Alternatively, the manufacturer’s standard stop, tail, turn, and backup lights may be used if they are the LED type and comply with FMVSS and California requirements. Retro-reflective tape reflectors (Ref. Petersen Mfg. #B490R and #B490A; or comparable), shall be used where needed to meet FMVSS requirements for Class A reflectors. Mounting holes for lights shall be the proper dimension as recommended by the manufacturer of the light. The holes shall be punched, plasma, or saw cut and finished smooth; torch cut holes are unacceptable.

All wiring installed by the supplier shall be the stranded copper type and shall have cross‑linked polyethylene insulation and be protected in flexible plastic sleeving (e.g., loom) for use in the cab shall be black polyethylene (80 °C) minimum and for under hood or under body shall be black nylon (120 °C) minimum (section 1.2.1.0 Sleeving https://dot.ca.gov/programs/equipment/ electrical/wires-cable-harness). Minimum gauge of wire to the lights shall be in accordance with SAE standards for distance from power source and load demand. Wiring color code for lights shall comply with SAE standard J560(b). The ends of all cut stranded conductors shall be mechanically stripped and fitted with weather proof connectors. NOTE: no splicing, cutting, or bullet-type plugs are acceptable on wiring looms or lights. The terminals shall be mechanically crimped securely with appropriate tool(s). All splices shall be sealed against moisture. Scotch Lock wire‑type piercing devices shall not be used.

Ground return connections shall be attached to the vehicle frame, body and/or electric motor. In cases where the electric motor or body is mounted on rubber or other insulation, proper ground shall be provided with grounding straps.

The edge of all metal members which wire harness or loom pass through shall be deburred, flanged, rolled or bushed with suitable grommets. In general, wire routing shall be such that maximum protection is provided by the vehicle sheet metal and structural components. All electrical work and installation of equipment/devices shall be completed in a workmanlike manner, mechanically and electrically secure. Devices, lamps, etc., requiring periodic service shall be serviceable and accessible by providing wire length to reasonably accomplish this.

WARNING LIGHTS:

Sweeper shall be equipped with the following warning lights:

AMBER LED LIGHT BAR: A 12-volt Amber LED Light Bar, (Ref. Whelen Model #CJ8CALT or Federal Signal Model # ALGT45S-CALDOT1 no exceptions) shall be supplied and center-mounted on sweeper cab roof. Exact location to be determined by manufacturer and Specification Engineer prior to installation. Light bar shall be visible front and sides when viewed at 4 feet above ground and at 100 feet away.

NOTE: If the amber LED light bar is not visible towards the rear at 4 feet above ground at 100 feet then the Amber LED Directional light stick shall be supplied.

AMBER LED DIRECTIONAL LIGHT STICK with CONTROLLER: A 12-volt Amber LED 8-cell Directional Light Stick with Controller (Ref. Whelen Model #CAWS825, or equivalent; no exceptions) shall be supplied and center-mounted at the rear of the sweeper. Exact location to be determined by manufacturer and Specification Engineer prior to installation.

The light bar controller and directional light stick controller (if needed) shall be placed within easy reach of the sweeper operator.

WORK LIGHTS:

Work lights shall be 12 V dc LED type with water resistant housing. Lights shall be shielded from debris and spray or positioned to minimize damage risks. Gutter broom and dump work lights shall have illumination design rating of at least 1700 lumens, Ref: Weldex WDWL-1R, Whelen 6 Nano, or equivalent.)

bs. Gutter Brooms: Forward and outer portions of gutter brooms shall be illuminated.

bt. Dump: Hopper dump chute shall be illuminated with 2 work lights.

bu. Front: Two additional lights shall illuminate roadway ahead of sweeper. Lights shall be fog type and meet SAE J583. Mounting height shall be within 12 to 30 inches from ground. Aiming shall comply with CA Vehicle Code 24403.

Illumination rating (per light) shall meet at least 1 of the following,

vii. At least 500 effective lumens or

viii. At least 100 lux at 10 m.

Example: KC Hi-Lites Gravity G4; Rigid D-Series; JW Speaker 6045/6050; or equivalent.

Gutter broom and front work lights shall switch On/Off together, per side. Switches shall be dash-mounted and labeled.

BACKUP CAMERA AND MONITOR:

Unit shall be equipped with backup camera and monitor. Rear view shall automatically display when vehicle is in Reverse gear. Display shall be clearly visible from operator’s normal driving position(s) without obstructing or reducing view through windshield or side windows, Ref. CVC-26708.

PAINT:

SWEEPING UNIT/SWEEPER: The basic unit and primary finish surfaces of any optional equipment shall be finish painted with lead-free Fleet White color. The finish coat shall be free from runs, drips, sags, etc., and shall be evenly applied to provide a gloss finish. The finish coat shall be lead-free from the following,

- Axalta Imron Elite Productive, EX, Polyurethane Enamel

- PPG Delfleet Evolution, FDSU, Ultra High Solids Polyurethane

- PPG Delfleet Evolution, FDGU, Ultra High Solids Polyurethane Enamel

- Sherwin Williams Genesis, GC, [G]LV, [Single Stage] Acrylic Polyurethane, NO EXCEPTIONS. All metal surfaces shall be primer painted in accordance with the paint manufacturer’s recommendations, not less than 2 mils dry thickness. Finish coat shall be Fleet White color referenced above, not less than 2 mils dry thickness (total of 4 mils). Paint thickness may be checked at time of inspection. Finish or top coat shall be compatible for re-coat or touch-up with above-referenced paint(s). Other minor or incidental component parts may be finished according to the standard factory finish. All paint and primer shall be lead free.

Optionally, the unit may be finished by powder coating. The powder coating shall be lead free (300 PPM LEAD MAX) and of a matching color to that specified above (Fleet White). Proper material preparation, application, and curing, as recommended by the powder coating manufacturer, shall be complied with. Color match of the proposed powder coating shall be approved by the Specifications Engineer prior to production.

EXCEPTION: Primer or paint shall not be applied to any poly tank surfaces (if supplied).

Purpose-built chassis frame and components shall remain the original factory colors. Any chassis mounting scars shall be repaired as necessary and refinished. Any paint overspray (on glass, paint, rubber, etc.) shall be removed and the surface returned to its original condition. All paint material used shall be comparable, as determined by the State, to those referenced above.

LUB…