Attachment_C_-_Specification_05387-032-211T.docx

STATE OF CALIFORNIA, DEPARTMENT OF TRANSPORTATION

DIVISION OF EQUIPMENT

SPECIFICATION NUMBER: 05387-032-211T

SPECIFICATIONS FOR: Truck-mounted 70-foot Personnel Hoist with Chip Dump Body

PURCHASE ESTIMATE NUMBER: 32-12-6320

05387-032-211T Attachment C 4/25/2022

TECHNICAL SPECIFICATIONS

It is the intent of this specification to describe the minimum requirements for a complete 70-foot overcenter personnel hoist (60-foot model with additional 10-foot pedestal elevator for a combined vertical reach of 70-feet), chip dump body, and other specified equipment; installed on a minimum 56,000-pound GVWR truck cab and chassis.

The unit shall be the manufacturer's standard production model(s) and shall be modified to meet these specifications. It shall be equipped with all the manufacturer's standard equipment and accessories which are part of the standard published literature. Optional equipment shall only be supplied and installed when included as a line item on the Purchase Order (PO).

The unit shall comply with Caltrans Equipment Quality Standards for Electrical, Welding, Paint and Coatings as defined at: https://dot.ca.gov/programs/equipment

DRAWINGS

TRUCK CAB AND CHASSIS

1. CAPACITY: The manufacturer's Gross Vehicle Weight Rating (GVWR) and Gross Combined Weight Rating (GCWR) shall not be less than 56,000 pounds and 80,000 pounds, respectively.

2. WHEELBASE: The wheelbase and cab-to-axle distance shall be determined by the aerial lift manufacturer to accommodate the aerial lift and body as specified below. Splicing or lengthening the original frame is not acceptable. The wheelbase shall be the same or similar length for both the diesel engine configuration and the compressed natural gas (CNG) fueled configuration. Diesel fueled vehicles shall include an additional storage box in lieu of the CNG fuel cabinet.

3. ENGINE:

DIESEL ENGINE: The engine shall be a current production model approved for sale in California, with a minimum of 410 gross SAE hp, and not less than 1450 lb-ft gross SAE torque per SAE J1995.

The engine shall be equipped with the following:

a. California Air Resources Board emissions certification. The engine shall meet all current Federal EPA emissions requirements ‘without the use of emissions credits’ at time of manufacture. Engine shall comply with CARB diesel engine, 5-minute or low NOx idle limits. If equipped, the engine’s 5-minute idle shutdown program shall ensure engine remains on during Power-Take-Off (PTO) use.

b. An air restriction gauge. The gauge shall be mounted where it is easily viewed during pre-op inspections (i.e. – may be dash mounted (preferred), or mounted under the hood). It shall be redlined for servicing or replacement as recommended by the engine manufacturer, must hold and maintain the highest reading, and be re-settable (Ref. Filter Minder Air Restriction Gauge, Model No. 168501, or equivalent).

c. An engine compression brake with multiple settings (Ref. Jacobs or equivalent).

d. A thermostatic controlled radiator fan.

e. An electronic hourmeter. The hourmeter shall be dash mounted to record engine running time (Ref. Hobbs Model 85006 solid state, or equivalent).

f. Cruise control.

g. Remote engine start/stop and throttle control if requested by the personnel hoist installer.

CNG-FUELED ENGINE: In lieu of the diesel-fueled engine described above, the engine shall be fueled by compressed natural gas (CNG). The engine shall be a current production model approved for sale in California, with a minimum of 400 gross SAE hp, and not less than 1450 lb-ft gross SAE torque per SAE J1995.

The CNG engine, injection system, ECM and software shall be installed by the cab and chassis manufacturer on the factory assembly line. The CNG fuel tanks and lines may be installed by a factory authorized sub-contractor.

All other requirements shall apply as listed above.

4. FRAME: The frame shall be full “C” channel construction. The RBM (Resistance Bending Moment) of the frame shall not be less than 2,000,000 in.-lbs. per rail, and a Section Modulus of not less than 16 cubic inches. The rails shall be fabricated from steel with a minimum yield strength of 110,000 PSI. Each rail shall be full length with no splicing or added extensions.

The front frame rails shall extend beyond the radiator grill to accommodate a custom front bumper with supports for the cab guard structure. If the optional front frame mounted winch is requested, longer front frame extensions may be required by the personnel hoist installer. Bolt on frame extensions shall only be allowed with written verification from the manufacturer that the extensions are equal or greater in strength than solid full length frame rails.

5. TRANSMISSION: The transmission shall be an Allison 4500 RDS 6-speed automatic transmission or equivalent having a primary shift schedule calibrated for maximum performance from the engine. If driveline speeds do not allow the use of 6th gear, it shall be electronically locked out while still providing the top speed requested in the rear tandem axles section. The transmission supplied shall be the correct capacity for use with the engine supplied. The cooling system shall incorporate a water-to-oil heat exchanger to maintain fluid at safe working temperature.

The transmission shall be factory-filled (or by the delivering dealer if not available from the factory) with synthetic transmission fluid. The fill location(s) shall be labeled to indicate the transmission has been filled with synthetic transmission fluid.

If an engine brake is supplied, then the shift pattern shall be set to provide progressive downshifting when the brake is activated. Any questions about this function should be addressed with the specification engineer.

If available, the “Auxiliary Function Range Inhibit (STD)” spare input function shall be supplied with the transmission and be available for aftermarket use.

Transmission controls and mounting shall be in accordance with the transmission manufacturer's specifications and recommendations.

An oil temperature gauge kit shall be supplied and installed in the dash. The temperature gauge shall be red‑lined to indicate the manufacturer's maximum recommended operating temperature or equipped with a visual or audible warning to indicate high temperature. The temperature sensor shall be located to indicate the highest oil temperature in the transmission.

The transmission as installed shall have a side opening clear for power take‑off mounting.

6. COOLING SYSTEM: The engine shall be equipped with the highest capacity radiator available with the truck model supplied. The radiator shall be equipped with a deaeration system and temperature controlled fan. A warning light or audible warning device for high coolant temperature shall be supplied and installed in the cab.

The radiator shall be equipped with a low coolant level warning light. This warning light shall be mounted in the dashboard and in view of the driver.

7. EXHAUST: The exhaust configuration shall be selected to minimize the wheelbase of the unit, while meeting all requirements of this specification. If multiple configurations are available, this item will be discussed at the post award meeting. Heat shielding or other protective material shall be provided for components exposed to exhaust and tailpipe heat and not meeting clearances recommended by the chassis manufacturer. This shall include wiring, hoses, body compartments, and individual components prone to heat induced failures.

8. FRONT AXLE & SUSPENSION: The Gross Axle Weight Rating (GAWR) of the front axle, springs, brakes, wheels, and tires shall not be less than 16,000 pounds. The front axle shall be sized to provide a minimum available payload capacity of 1,200 pounds on the complete unit.

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. The hubs shall be labeled to indicate they have been filled with synthetic lubricant.

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

9. REAR TANDEM AXLES & SUSPENSION: The rear axles shall be single reduction tandem axles, with a minimum combined Gross Axle Weight Rating of 40,000 pounds for the axles, springs, brakes, wheels, and tires. The gear ratio supplied shall provide a maximum speed of no less than 70 mph in the highest transmission gear and at the engine manufacturer's governed RPM. The rear interaxle differential shall be provided with a driver-controlled switch to lock the power divider between the front and rear tandem axles. An additional driver-controlled switch shall be provided to lock the differential side-to-side on both axles. This function shall automatically disengage above a factory recommended speed to prevent damage.

The hubs shall have oil lubricated wheel bearings and an oil seal (Ref. Stemco Guardian Hub Seal or equivalent).

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

The rear suspension shall have a rated capacity of not less than the GAWR of the rear axles and shall include equalizing beams to distribute the load (Hendrickson RT, or equivalent).

10. BRAKES: Full air disc brakes shall be supplied on all axles to match the axle load rating. The brake system shall comply with all Federal Motor Vehicle Safety Standards (FMVSS). The following shall be supplied and installed:

a. A minimum 12 CFM air compressor. Air for the compressor shall be filtered air taken from the air cleaner or air cleaner induction system.

b. An air dryer (Bendix Model AD‑IP, or equivalent).

c. A 2‑axle trailer towing package complete with all controls (foot and hand controls). Controls shall be mounted and air lines terminated at the end of the frame with glad hands and covers. The service line shall be on the left side of the truck and the emergency line on the right side. The parking brake controls shall include either a tractor only parking brake control or an integrated type control that will allow the release of the trailer spring brakes without releasing the truck parking brakes.

d. An electronic trailer brake controller wired to the trailer 7-wire socket in accordance with drawing U1-A010-01.

e. One (1) or more air accessory outlets with pressure protection valves. Any air accessories shall be fed through a pressure protection valve.

f. The parking brake shall be spring activated. All spring chambers shall be anti-compounding. On tandem axles, spring brake chambers shall be supplied on both axles.

g. Dust shields

h. ABS (Anti-lock Brake System). A minimum 4-channel system shall be supplied. The system shall have a 4-channel system with automatic traction control. The automatic traction control shall monitor wheel speed and work in conjunction with the vehicle Anti-Lock Brake System (ABS) to limit traction loss during acceleration.

11. WHEELS: Ten (10) steel disc wheels shall be furnished. The wheels shall be drop center tubeless type designed for use with radial tires. All wheels shall be hub piloted. Dual wheels shall be mounted using two-piece flange nuts. All wheels supplied on the order shall be of the same make and model (front and rear wheels may differ in model). Wheels shall have a minimum of two (2) hand holes per wheel. All wheels shall be painted white in color.

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

Tire chain clearance shall be provided for dual tire chains with triple side chains. The clearance shall conform to the requirements of SAE J683.

12. TIRES: Ten (10) steel belted radial tubeless type tires shall be furnished and installed. The front tires shall be at least 315/80R22.5, Load Range ‘L.’ The rear tires shall be mud traction type for on and off-highway use, size 11R22.5, minimum Load Range ‘G’. All tires supplied on this order shall be of the same make and model (front and rear tires may differ in model).

13. CAB: The cab shall be a conventional cab design, enclosed with an approved safety glass windshield, tempered glass rear, and power side windows. The cab shall be rubber and/or air suspension mounted and shall have a front‑tilting hood and fenders.

A wire mesh screen, constructed from corrosion resistant metal, shall be installed behind the grille. NOTE: Bug screens constructed of flexible material and installed in front of the grill will not substitute for the metal screen described.

The following items, supplementing, if necessary, those items already cataloged as standard cab equipment, shall be furnished and installed:

a. Air conditioner, heater and windshield defroster with multi-speed fresh air and recirculation ventilator system.

b. Auxiliary power outlet (12V cigar lighter type).

c. Power locks and windows for driver and passenger door.

d. Right and left outside rearview mirrors, not less than 90 square inches in size. The mirrors shall be electronically heated with power adjust feature. Mirrors shall be OEM factory installed, aerodynamic breakaway type, factory standard color, preferably black or grey.

e. A downward-viewing convex mirror, located above the passenger (right) door window.

f. Dual windshield wipers. Electric powered wipers shall be supplied with an intermittent feature.

g. Dual windshield washers.

h. Tilting steering wheel. Tilt and telescope functions shall be provided if available.

i. Full instrumentation, including but not limited to the following: speedometer, tachometer, coolant temperature, primary and secondary air pressure, fuel level, and voltmeter. Warning lights shall not substitute for readable indicating instruments. All gauges shall be mounted in the dash or in a factory auxiliary panel.

j. Daytime running headlights.

k. Steps and grab handles to safely enter and exit the cab from both sides.

l. Glove compartment or other storage compartment.

m. Dome light. Light shall be activated by opening the driver door, the passenger door, and by a switch in the cab.

n. Floormats, headliner, and full cab insulation. Bare metal or fiberboard will not be considered as insulation.

o. Driver and passenger seat shall be air-suspension type bucket seat with high back to support head and shoulders, and lumbar support. Seat cover shall be cloth or vinyl with a cloth insert.

p. Dual armrests for each seat.

q. Cab interior shall be brown or grey in color; or as deemed appropriate by the State.

r. Dual visors.

s. Standard AM/FM radio complete with speakers, antenna, and Bluetooth connectivity.

t. Locking cab, with all locks keyed alike and 3 keys supplied.

u. Frame mounted air horn(s).

v. Dedicated (“clean”) power leads, 12 volt positive and negative for a two-way mobile radio, shall be provided to the cab and labeled. The two-way communication radio will be installed by Caltrans personnel.

NOTE: All gauges and controls shall be marked/identified for function and use in English. The markings shall be explicit, legible, and permanent. International symbols may be used to supplement (not in lieu of or predominate over) the above. Any precautionary signs shall be similarly marked. All gauges shall be panel mounted, shall be consistent in size, color scheme, pointer design, and label style and size. All gauges shall be adequately illuminated for nighttime operation, with an infinitely variable brightness control from full bright to off. Gauges mounted below the dash are not acceptable. All gauge placement shall provide ready visibility to the operator.

14. FUEL SYSTEM:

Diesel fueled vehicle: The total diesel fuel capacity shall be a minimum of 70‑gallons. The fuel tank design shall maximize clear cab-to-axle space. Each tank shall have a filler opening. Each tank shall be equipped with a drain.

A diesel exhaust fluid (DEF) tank shall be sized and located as recommended by the chassis manufacturer. The DEF tank capacity shall be no less than 6 gallons.

CNG FUELED VEHICLE: The CNG engine, injection system, ECM and software shall be installed by the cab and chassis manufacturer on the factory assembly line. The CNG fuel tanks and lines may be installed by a factory authorized sub-contractor. The chassis manufacturer or final vehicle manufacturer must support and warrant all work performed by the sub-contractor including parts and service support. The CNG tank sub-contractor shall adhere to the fuel system requirements described below.

The fuel tank(s), plumbing, fittings, etc. shall be rated for 3,600 PSI minimum. All components shall be as recommended and approved for use in high pressure CNG fuel systems and shall comply with all requirements of the engine manufacturer. The fuel system shall have fuel filling ports located on both sides of the vehicle. The fueling ports shall be NGV1 style and compatible for use with 3,600 PSI and lower pressure filling stations. The system shall be equipped with a replaceable fuel filter in the system. A coupling, meeting ISO 7241-1(Series-B) profile (Ref. Parker SH2-63-643) for de-fueling the tank, shall be installed on the high-pressure side of the regulator. The de-fueling port shall have a shut-off valve and a method to relieve pressure between the valve and coupling. There shall be a tank pressure gauge located near each fueling port, and a fuel capacity gauge installed in the dash. The fuel cylinders shall have a minimum 72 diesel gallon equivalent fuel capacity.

The fuel system, cylinders, and enclosure shall be fabricated and installed in accordance with the current NFPA 52 requirements. The fuel cylinders shall be type III or type IV and meet the requirements of all applicable standards for compressed natural gas cylinders including but not limited to Federal Motor Vehicle Safety Standards 304 and ANSI/CSA NGV2. The fuel tanks and enclosure shall be installed on the frame rails directly behind the cab. The mounted fuel tank enclosure shall not exceed the following:

a. Width: 98 inches

b. Height: 4 inches above the cab

c. Depth: 30 inches from back of cab to rear most point of enclosure All vehicle dimensions (Wheelbase, CA, CF, GVW, etc.) and component strength ratings shall be adjusted to accommodate the CNG tanks and other system components such that the vehicle performance and payload capacity are not compromised. The warranty for the entire fuel system shall be 3 years/36,000 miles or equivalent to chassis warranty, whichever is greater. The warranty period shall not begin until the unit is put into service.

15. SWITCH PANEL: If required by the personnel hoist installer, factory switches shall be provided.

16. REAR-VIEW CAMERA AND MONITOR: If requested by the personnel hoist installer, a factory rear view camera installation kit and/or wiring provision shall be supplied.

17. ELECTRICAL EQUIPMENT (CAB & CHASSIS): Minimum electrical equipment shall comply with all Federal Motor Vehicle Safety Standards and State of California Department of Motor Vehicle regulations. The stop, tail and turn signal lamps shall be in combination, and the wires to these lamps shall be in loom or conduit. A minimum 160‑amp alternator with a matching regulator shall be furnished. The battery system shall be made up of 12‑volt accessible maintenance free batteries (Ref. Delco's Freedom or equivalent). The system rating shall be not less than 1,800 CCA (cold cranking amps) at 0°F. and a reserve capacity of not less than 425 minutes at 25 amps and 80°F. Ratings are as established by BCI (Battery Council International) and SAE. Side terminal batteries are not acceptable.

Re-settable circuit breakers shall be supplied in lieu of fuses where available.

A seven conductor jacketed cable and light wiring socket for a trailer jumper cable, shall be wired to the end of the frame, to be installed later by the personnel hoist manufacturer. The wire color code and wiring of the socket shall be in accordance with the attached wiring schematic, Drawing No. U1‑A010‑01. The cable shall be one piece (no splices) from the cab or engine compartment to the end of the frame.

18. PAINT – CAB AND CHASSIS: The cab, hood, and fenders shall be finish painted with lead-free Winter 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 or top coat shall be compatible for re-coat or touch-up with lead-free Axalta Imron Elite Ex 2.8 VOC, Winter White (#N6431EX), polyurethane enamel; PPG Delta DUHS (#90604); or Sherwin Williams Genesis (#G8-40687). Other components may be finished according to the factory standard finish.

PERSONNEL HOIST TECHNICAL SECTION

A 70-foot overcenter articulating personnel hoist (60-foot model with additional 10-foot pedestal elevator for a combined vertical reach of 70-feet) shall be supplied and installed to meet the requirements of this section.

19. MOUNTING LOCATION: The personnel hoist pedestal shall be mounted behind the cab with the bucket stowed over the cab and the boom stowed over the chip dump body. The elevator section shall be mounted longitudinally to the truck frame to allow storage compartments on each side.

20. PERFORMANCE CHARACTERISTICS:

a. Travel Height: The traveling height shall not be over 13 feet 6 inches.

b. Vertical Reach: The distance from ground to bottom of bucket with the lift and elevator at maximum vertical extension shall be not less than 70 feet.

c. Horizontal Reach: The horizontal distance from centerline of rotation to outer lip of bucket shall be not less than 44 feet at zero (0o) elevation.

d. Lower Boom Articulation: Lower boom shall have a minimum articulation from 0o to 125o from horizontal.

e. Upper Boom Articulation: Upper boom shall have a minimum articulation from 0o to 245o.

f. Capacity: The personnel hoist capacity rating shall be not less than 400 pounds in any position.

g. 360° Continuous Rotation

21. ACTUATION: The unit shall use hydraulic cylinders for elevation and articulation with pilot operated check valves. The rotational mechanism shall be driven by hydraulic motor.

22. LOWER BOOM: The lower boom shall be fabricated from high strength tubular steel and have a minimum insulation gap of 15-inches.

23. UPPER BOOM: The upper boom shall be equipped with an insulated conduit for routing hydraulic lines.

The upper boom and bucket design shall qualify the unit as an ANSI A92.2 Category B insulated aerial device, at minimum.

There shall be an automatic locking device for the upper boom. The automatic locking device shall allow the upper boom to automatically stow and unstow.

24. LIFTING HOOK: A lifting hook shall be attached to a pad eye attached to the center of the end of the upper or lower boom. (Ref: Crosby/Laughlin hook, 1/2 ton capacity, no. S‑3316 and a Crosby S‑264 pad eye #2 Broadus Chain and Cable). Decals stating the lifting capacity and "Hook to be used with no personnel in basket” shall be affixed near the hook.

25. BOOM SADDLE: The boom saddle and the rear of the dump body shall have sufficient strength to carry the boom unsupported by hydraulics. The boom saddle shall be mounted to the rear of the dump body. The cradle of the boom saddle shall be padded.

26. NEUTRAL POSITION INTERLOCK: If available, the automatic transmission Auxiliary Function Range Inhibit spare input shall be deactivated when the boom is not seated. This will prevent neutral-to-range shifting when the boom is not seated.

27. PERSONNEL BUCKET: A personnel bucket measuring no less than four (4) square feet opening and 40-inches deep shall be mounted on the end of the upper boom section. The bucket shall be rectangular, be constructed of molded reinforced fiberglass plastic, and have the following:

a. The bucket shall have its maximum capacity labelled on two (2) sides. The lettering shall be legible from the ground when the bucket is installed and operational.

b. A waterproof quick removable cover.

c. Self‑leveling mechanical linkage or hydraulic actuation regardless of the boom angle.

d. The bucket shall include a hydraulic rotation feature. The bucket shall rotate 90-degrees around the end of the boom.

e. An insulating liner.

f. A minimum of one interior and one exterior step for ease of ingress and egress.

g. A safety harness and a lanyard with attaching ring.

h. A manufacturer standard tool tray designed to hang over lip or edge of the bucket.

i. One (1) set of hydraulic tool outlets accessible at the personnel bucket, convenient to the operator.

28. LOWER CONTROLS: The lower control station shall contain a manually actuated selector valve, which must be operated before control of any boom functions can occur from the lower station. This valve, when actuated, shall neutralize the bucket controls. The valve shall be equipped with a detent requiring manual return to neutral.

The controls shall be the hydraulic metering type. All control valves shall have feathering qualities, for precision positioning of the boom.

Lower controls will be for the following:

a. Pedestal rotation.

b. Lower boom raise and lower.

c. Upper boom unfold and fold.

d. Elevator raise and lower

e. Engine stop/start

f. Throttle speed control

29. BUCKET CONTROLS: Bucket controls shall be designed for one hand operation. All controls shall be weatherproof. Control lines to the bucket shall be interior to the boom.

Bucket controls shall include the following:

a. Single stick control with safety interlock (deadman) trigger.

b. Pedestal rotation.

c. Lower boom raise and lower.

d. Upper boom unfold and fold.

e. Elevator raise and lower

f. Engine stop/start

g. Throttle speed control

30. OUTRIGGERS: Two (2) hydraulically operated outriggers shall be provided to stabilize and operate the hoist and load safely. The outriggers shall be welded to the hoist pedestal.

The outrigger maximum spread shall be the minimum allowable width required for stability. When fully extended the outriggers shall extend down 5- to 8-inches below grade level. When fully retracted, the outriggers shall be no wider than the overall width of the vehicle and body. The outriggers shall have flexible (swivel) pads and/or up-turned outer edges to prevent damage to pavement.

Two sets of outrigger controls shall be installed, with one set located at the rear corners of the truck and a second set located at the sides of the front bumper. Controls shall be located as far to the side of the vehicle as possible to allow maximum view of the outrigger being operated. A spirit level shall be mounted by each outrigger control.

Outriggers shall be protected by pilot-operated check valves to prevent creeping out when in stowed position and from collapsing in the event of line failure.

Outriggers shall be connected in series to an interlock system to prevent the boom from being operated without the outriggers being extended. The interlock shall not release the boom until the outrigger foot touches the ground. The force produced by the ground pushing on the foot shall release the interlock regardless of how far the outrigger is extended.

Once the outrigger interlock has been released and the boom has been removed from the boom rest, hydraulic power shall be available to the boom controls even if an outrigger foot loses ground pressure. The outriggers shall not be capable of being stowed until the boom has been stowed.

31. AUXILIARY OUTRIGGER PADS: There shall be one auxiliary outrigger pad per outrigger supplied. The pad shall be not less than 18” x 18” in surface area, not less than one (1) inch thick, and constructed of material that is highly resistant to stress, cracking, and chipping. The pad shall be equipped with a handle. Wood pads shall not be acceptable. Outrigger pad storage shall be provided on or under the body, on both sides.

HYDRAULIC SYSTEM TECHNICAL SPECIFICATIONS

32. HYDRAULIC SYSTEM BASIC DESCRIPTION: The hydraulic system shall be designed to operate at the maximum required pressure with a minimum safety factor of four. The hydraulic system shall be equipped with the manufacture's recommended filters, filter condition indicators, relief valves, and reservoir(s). The hydraulic system shall maintain oil at recommended operating temperature, pressure, flow rate, and purity; and conform to the following additional requirements.

33. HYDRAULIC LINES AND FITTINGS: 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 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 pipe, galvanized pipe or plastic pipe or fittings, etc. shall not be allowed in the hydraulic system, including the low pressure return side. Brass ball valves and fittings may be used in the low pressure side of the system only. Only steel or stainless steel crimp type hose fittings and ends which are approved for hydraulic use shall be used (Aeroquip or comparable).

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).

34. PUMP: The pump shall have enough capacity to supply the personnel hoist at the manufacturer rated speed and operate the tool circuits simultaneously. The pump shall have check valve protection from the emergency hydraulic pump described below.

35. RESERVOIR: The reservoir shall have a strainer and a filtered weatherproof breather cap.

36. FILTER: The hydraulic filter shall have a filter condition indicator installed to identify when the filter requires changing. The filter assembly shall be installed in a location convenient for replacement without draining the reservoir.

37. IN LINE VALVES: The line between the strainer and pump shall have a ball valve at the tank. The return line shall also have a ball valve above the return filter such that the filter may be removed without draining the system.

38. OVERSTOW PROTECTION: Overstow protection shall be supplied to prevent lower boom or body damage due to excessive pressure of the boom against the boom rest when stowing the boom. This system shall not interfere with normal boom operation with the boom out of the boom rest.

39. Hydraulic Tool Circuit: One hydraulic tool outlet, supply and return, with shutoff-type quick connect couplers shall be supplied and installed at the bucket. The couplers shall meet NFPA’s flush face quick connect coupler requirements. Couplers shall be HTMA Standard, Faster 2-FFN 38 series, Base Size 06. The tool circuit shall have a bypass-type flow control valve.

40. EMERGENCY HYDRAULIC POWER: Emergency hydraulic power shall be able to operate the hoist if the main power source is inoperable. Power shall be supplied by a check valve protected, 12V DC motor driven hydraulic pump. The emergency system shall be tied into the main hydraulic system to use all main system components. The emergency system shall be operable from both the bucket and the lower control station.

BODY AND STORAGE TECHNICAL SPECIFICATIONS

41. BODY, GENERAL ASSEMBLY: A chip dump body shall be supplied and installed complete with an underbody hoist. The body shall be 11-feet long, 96 +/- 2-inches wide, and no less than 60-inches tall.

The rear section of the body shall be reinforced to support the boom in the stowed position.

The body shall include a hinged rear tailgate or dual hinged gates across the rear opening. The tailgate(s) shall hinge at the side and be designed to fully swing open to be flat against the body. Each gate shall mechanically secure to the body in the open position.

When mounted on the cab and chassis, there shall be sufficient space between the front panel of the body and the rear of the cab for the installation of the pedestal, elevator, and outriggers.

Compartment dimensions may vary in accordance with industry standard bodies, if approved by the Specification Engineer.

42. BODY CONSTRUCTION: The body and superstructure shall be constructed entirely of steel and electric arc or resistance welded throughout to form a weatherproof and dust tight unit. All compartments shall be formed using watertight and dust tight construction.

Sheet metal screws shall not be used at any point in the fabrication of this unit. Bolts, if used, shall be steel, solid shank, of proper size and spacing to provide ample strength for the purpose intended. Exposed joints shall be weatherproof and dust-tight.

The floor plate shall be ribbed, or made rigid in some other acceptable manner and shall be supported on a substantial steel frame of cross members and stringers.

Sheets and panels shall be reinforced wherever necessary to provide a proper degree of rigidity. All exposed edges of fenders, door panels, and shelving shall be folded, or otherwise stiffened and smooth. Do not bead edges to stiffen.

The floor in the load space shall have drainage outlets in the front section of body. All compartments shall have a drainage outlet sealed with a removable plug or one way drain outlet.

43. UNDERBODY HOIST: The dump body shall be equipped with an underbody hoist with the following requirements:

a. The hoist shall be capable of a dump angle of not less than 45°.

b. The hoist shall have a minimum rated capacity of 6.5 tons and shall be listed as a minimum class 20 hoist by the National Truck Equipment Association (NTEA).

c. The manufacturer’s tag for the hoist shall be mounted to provide easy visibility. The manufacturer’s tag shall be complete with manufacturer, model, and hoist serial number.

d. The underbody hoist and booms shall be connected to an interlock system to restrict boom operations when the underbody hoist is operated.

e. The hoist and rear pins shall be mounted to the truck frame in accordance with the hoist manufacturer’s recommendation.

44. STANDARD SAFETY PROP: One or more standard safety prop(s) shall be installed beneath the dumping body to prevent the raised body from falling in case of hydraulic failure. The design of the safety prop(s) shall allow each to be deployed and stowed safely from the side of the unit.

45. PULL OUT LADDER: A pull out ladder shall be installed at the rear of the body to provide access to the bed. The bottom step of the ladder shall not be more than 21 inches from the ground and the step spacing shall not exceed 12 inches. One or more hand holds shall be supplied inside the body to provide for three-point contact during ingress and egress.

46. INTERIOR COATING: The interior of the dump body shall be coated with a protective epoxy finish (Ref. Sherwin Williams TarGuard, B69B60 & B69V60, or comparable). The epoxy shall be not less than 8 mils dry film thickness.

47. SHOVEL AND BROOM HOLDER: A shovel and broom holder shall be supplied and installed inside the chip dump body at the rear. It shall be designed to hold 3 long-handled tools. The holder shall be bolt-on or otherwise readily removeable.

48. CHIP BODY CURB-SIDE STORAGE COMPARTMENT: Through interior storage shall be supplied on the curb-side of the body. The compartment(s) shall be no less than 12-inches wide, shall extend the full available length of the body, and shall be approximately two-thirds of the interior height of the body at its outermost taller side. Each compartment shall have two evenly spaced shelves. There shall be a vertical door opening to the rear. Two or more doors shall be installed on the curb-side face of the body to provide maximum access to the interior of this compartment. The size and spacing of these side-access doors shall be as recommended by the contractor. The following factors shall be taken into consideration, at minimum: location of body vertical bracing, reasonable height from the ground for all door latches, access to all three shelf levels from no less than one side door (potentially oriented vertically at the foremost end).

49. CROSS BODY STORAGE BOX (diesel vehicle only): For diesel fueled vehicles, in lieu of the behind-cab CNG fuel enclosure, a cross body storage box shall be supplied and installed. The box shall be suitable for use with the above-described chip dump body and hoist pedestal. The box shall be approximately 26” wide and shall be as large as possible for the space available. The height shall extend no less than 48-inches above the frame. This box shall be installed fore or aft of the hoist pedestal assembly and outriggers; either directly behind the cab or directly forward of the chip dump body. The box shall have a vertical door with a lockable latch on both the curb and street sides. The box shall have a through compartment with no fewer than two sliding shelves that can extend out each compartment door as far as possible.

50. STREET-SIDE STORAGE COMPARTMENTS: Storage compartments shall be supplied and installed along the street-side length of the personnel hoist pedestal and elevator subframe. The compartment width and depth shall be sized as large as possible for the space available dependent on the dimensions of the personnel hoist components. The overall width shall be no less than 66-inches and depth shall be no less than 20-inches. This street-side box shall be approximately 50-inches tall and shall be divided into three vertical sections. Two sections shall be combined into a single compartment with two overlapping vertical doors. The third section shall have a single vertical door. Each street-side compartment shall include no less than two adjustable shelves mounted on vertical rails (Unistrut or b-line channel style) for infinite height adjustment. Near the top on each side panel and rear face, a horizontal rail shall be installed for installation of rope hooks or other accessories. A minimum of eight swivel rope hooks shall be supplied and installed.

All compartments shall be louvered or otherwise vented on the doors or compartment walls.

51. CURB-SIDE STORAGE COMPARTMENTS AND PLATFORM ACCESS: Storage compartments and platform access steps shall be supplied and installed along the curb-side length of the personnel hoist pedestal and elevator subframe.

One main storage box shall be installed in the foremost position and function as part of the platform access steps. The width and depth shall be sized as large as possible for the space available. The overall width shall be no less than 44-inches and depth shall be no less than 20-inches. This storage box may include a single compartment with overlapping double doors, or two separate compartments with vertical doors.

This storage box shall include 2-3 levels of deep pull-out drawers with removable dividers. Each drawer shall be as wide as possible for the compartment opening and approximately 10-14 inches deep. A single shelf shall be installed above the drawers, space permitting.

These compartments shall be louvered or otherwise vented on the doors or compartment walls.

52. COMPARTMENT DOORS: Each compartment shall be provided with doors opening outward. Side compartment doors shall hinge at the front. Rear compartment doors shall hinge on the outmost edge. All doors shall be equipped with manually detachable chain type or gas strut type door stays. All doors shall be vented.

The doors and seals shall be designed to allow maximum opening to each compartment. Doors shall be constructed with weatherproof and dustproof seals. All doors shall be fitted with rods not less than 5/16-inch diameter (plastic or nylon hinge brackets will not be acceptable). Comparable hinge designs may be acceptable with prior written approval from the State. Door latches shall be three-point twist locks with recessed pocket and D-ring or chrome "T" handles. The three-point latches shall be located on opposite ends of the door and at the center.

The handles or door locks shall not be readily removable from the outside. Means for securing locking doors shall be provided by either individual keyed locks or by master lock bars with single locks. All compartment locks shall be keyed alike, and not less than three (3) keys shall be furnished.

53. WATER JUG RACK: A standard water jug rack shall be supplied and installed accessible from the curb-side of the vehicle. The rack shall be designed to secure a standard 5-gallon water jug. Alternatively, two separate 2.5 to 3-gallon water can racks may be supplied and installed. The location of the water jug rack(s) shall be determined at the post award meeting.

COMPLETELY ASSEMBLED UNIT TECHNICAL SPECIFICATIONS

54. SWITCH PANEL: A switch panel (Ref: Wired Rite Systems, Inc., Power-Up Products, or Transportation Safety Devices, Inc. or equivalent) shall be supplied and installed in the truck cab containing the following switches, legends, and indicator lights:

a. A PTO legend and switch. An indicator light shall indicate when the PTO is engaged.

b. Amber warning lights

c. Work light legend and switch

d. Boom not stowed legend and red indicator light.

e. Outriggers not stowed legend and red indicator light.

f. A PTO hour meter shall be supplied and installed in the switch panel and operate only when the PTO is operating.

g. Minimum of one (1) blank legend and switch slot.

The switch panel shall be “hot” when the truck ignition key is in the IGNITION/ON position. The amber warning lights and work lights shall operate when the truck ignition key is in the IGNITION/ON position, and whether the PTO is engaged or disengaged.

The switch panel shall be installed within convenient reach of the driver and be manufactured to fit integrally with the dashboard of the vehicle unless otherwise approved by Caltrans. The switches shall be magnetic type circuit breaker switches. The circuit breakers shall not re‑set unless the overload has been corrected. The wiring shall not include fuses or thermal circuit breakers for individual circuits and it shall be isolated from the truck wiring system.

The switch panel hot lead shall be protected by a master circuit breaker. The master circuit breaker shall be waterproof, have a push button disconnect for servicing, and be installed as close to the battery as possible. The switch panel shall be hot only with the truck ignition switch in the on position.

The legends shall have two levels of back‑lighting intensity or be otherwise illuminated. The low level shall be activated when the ignition switch is turned on. The high level shall be activated only when the individual switch is activated. The lights shall be solid state type and red. Each legend shall be labeled with the wording requested by Caltrans.

Final approval from the Division of Equipment, Specifications Engineer, for the switch panel configuration shall be obtained by the Contractor before panels are purchased.

IN LIEU OF THE ABOVE-DESCRIBED SWITCH PANEL: If the truck cab and chassis is supplied with a multi-plex electrical system, (wiring, switches, warning notifications, etc.), the above-described switch panel may not be required. If ALL required switches, warnings, hour meter, and other capabilities can be accommodated through the use of the vehicle multi-plex electrical system, vehicle switches, etc., they may be able to be used in lieu of the described switch panel.

The supplier of the truck cab and chassis and the supplier of the personnel hoist shall determine the compatibility of the vehicle multi-plex electrical system with the requirements of the personnel hoist. All functions described and required of the pre-wired switch panel must be accommodated.

55. BACK-UP CAMERA AND MONITOR: A camera providing video display that aids the driver’s view behind the vehicle shall be supplied. The camera shall be activated when the gear selector is placed in reverse and shall turn off when the selector is moved to another gear position. If available, a control shall be included to allow manual activation of the camera at any time. A video monitor shall be located so that it is clearly visible from operator’s position without obstructing or reducing the driver’s clear view through the windshield or side windows, CVC-26708(2). Location of the monitor shall be approved by the Specification Engineer.

56. TOW HOOKS: Front tow hooks shall be installed, or other provision for towing the vehicle.

57. CAB PROTECTOR AND BUCKET ACCESS: A protective platform shall be installed over the cab.

The dimensions of the front bumper and width of the platform shall be designed to ensure the chassis hood does not come into contact with the front vertical supports when opened.

Access from the ground to the platform shall be a step style design integral to the curb-side storage compartments and installed in accordance with all applicable OSHA standards. Hand holds shall be installed to provide 3-point contact at all times. Each step surface shall include a grip material design or non-slip coating. A fixed ladder style access is not acceptable unless supplied in addition to the step style access.

A bucket rest for the personnel bucket shall be installed on the cab protector.

58. SIGNS: The following durable signs, with lettering legible at 12 feet, shall be supplied and placed visible to the operator:

a. Two (2) each signs shall read: "UNLAWFUL TO OPERATE THIS EQUIPMENT WITHIN 10 FEET OF HIGH-VOLTAGE LINES OF 50,000 VOLTS OR LESS." In addition to the above wording, the following statement in small lettering shall be provided on the warning signs: "For Minimum Clearances of High-Voltage Lines In Excess of 50,000 Volts, See California Code of Regulations, Title 8, Article 37, High-Voltage Electrical Safety Orders."

b. Sign(s) describing emergency operating procedures. The sign(s) shall be posted at the point of the emergency operation within plain view. For example, a sign describing procedure for bleeding boom cylinders to let the bucket operator down would be posted in sight of the bleed valve. A plate with a comprehensive description of the emergency let down procedures posted at the pedestal will be acceptable.

59. EMERGENCY LET DOWN TOOL(S): Any tool, other than a common wrench or screwdriver, required for any emergency let down procedure shall be supplied with each unit.

60. AIR LINE: An airline shall be plumbed from the truck air tank through a pressure protection valve to a location on the curb-side of the vehicle. The airline shall have a ¼-inch NPT shut-off type quick disconnect fitting on the end. The quick disconnect shall be located on the curb-side near the front of the body.

61. MUD FLAPS AND SPLASH GUARDS: Mud flaps and splash guards shall be installed to the front and rear of the rear tandem axles. Mud flaps shall be the anti-sail type.

62. TOWING PROVISIONS: Unit shall be equipped with the following:

a. Formed rear crossmember of 1/2-inch-thick plate, minimum, welded to frame rails.

b. A pintle hook (Premier 580 or equivalent) shall be supplied and installed with a 29 +/- 1 inch height to the center of the hitch eye from level ground. The rear crossmember may need to be reinforced to support the rated load of this pintle hook.

c. Industry standard towing safety chain hangers or D-rings welded to rear crossmember.

d. Welded or bolt-on eyelet for trailer breakaway brake cable located left of pintle centerline.

e. 7-Wire plug wired as described in the Electrical Equipment sections.

f. Glad hands, 180° swivel type with Service air on left side and Emergency air on right side. Glad hands mounted at the same height to each other, equally spaced apart, approximately 13 inches from pintle to each glad hand centerline.

63. LICENSE PLATE HOLDER: A license plate holder with a license plate light shall be supplied and installed.

64. AMBER WARNING LIGHTS: Warning light configuration specified shall be installed for 360-degree visibility around the truck. Visibility shall be referenced from 100 feet beyond truck, at height of 4 feet above ground with boom in any position. Installation shall comply with Caltrans Equipment Quality Standards and light manufacturer’s instructions. Wiring to lights shall be protected and include spare length for serviceability. This shall include the following, at minimum:

a. Two (2) rear facing flashing amber LED lights shall be supplied and installed on the rear face of the body. The lights shall be located as high as possible and shall be controlled by a switch in the cab. The lights may be round (Ref: Federal Signal Part No. 607130-02, or equivalent) or rectangular (Ref: ECCO Part No. ED3706A, or equivalent).

b. A directional warning light stick shall be supplied and installed at the rear of the body on the roof. The light stick shall be sufficiently guarded from impact. The arrow stick shall be Whelen model CAWS825, or equivalent. It shall be wired to a controller mounted in the cab, easily accessible to the driver.

c. Two (2) forward facing flashing amber LED lights shall be supplied and installed at the front of the cab protector.