ITB127 - Attachment 2 - Requirements and Specifications.docx

ITB127

ATTACHMENT 2 – REQUIREMENTS & SPECIFICATIONS

SECTION 1: GENERAL REQUIREMENT

1. Orders & Deliveries Meetings

1.1. Kickoff Meeting - the Contractor must attend a kick-off meeting located at ITD’s HQ facility (3311 West State Street, Boise, ID 83703), within ten (10) Business Days after the order is placed. This meeting will be used to introduce key personnel, review the specifications to include component placement and drawings, and to address any questions or concerns.

1.2. Progress Meetings - The Contractor must attend a Progress Meeting located at ITD’s HQ facility (3311 West State Street, Boise, ID 83703), or by conference call, one (1) time per month. This meeting will be used to: 1) reviewing progress of the Equipment as it relates to the delivery schedule, 2) identifying potential risks and solutions to avoid or mitigate those risks, and 3) addressing any other questions or concerns

Orders & Deliveries 1.

2.

2.1. Orders

2.1.1. After receipt of the order from ITD, the Contractor must provide a delivery schedule for the order. The delivery schedule must identify the quantity of Equipment that will be ready for inspection and delivery to ITD each month (see minimum quantity requirement below).

2.1.2. The Contractor must confirm the receipt of each Order and provide the following to ITD’s CMT within ten (10) Business Days after receipt of each Order:

2.1.2.1. The required lead-time for the Order. The lead-time must account for the time needed by the Contractor to get all labor, materials, and equipment ready to begin work on the Equipment.

Note: Pilot has different delivery timeline (see Section 4, below). For the Order with Pilot, the Contractor must provide one (1) lead-time for Pilot, and one (1) lead-time for the remainder of the Order.

2.1.2.2. A delivery schedule for the Order. The delivery schedule must identify the quantity of Equipment that will be ready for inspection and delivery to ITD each month (see minimum quantity requirement below). This plan will be reviewed monthly during Progress Review Meeting (see Attachment 6-Contract Management).

Note: Pilot has different delivery timeline (see Section 4, below). For the Order with Pilot, the Contractor must provide one (1) delivery schedule for Pilot, and one (1) delivery schedule for the remainder of the Order.

Deliveries 1.

2.

2.1.

2.2.

2.2.1. All ITD owned truck chassis will be drop shipped from the truck manufacturer’s facility to ITD Headquarters Garage located at 3311 West State St Boise ID, 83714. It shall be the Contractor’s responsibility to pick up and haul (not drive) the truck chassis from ITD’s Headquarters Garage to the Contractors up fitting facility if the facility is more than fifty (50) miles from ITD Headquarters Garage Location. If the contractor’s facility is less than fifty (50) miles from ITD Headquarters garage location, the truck chassis can be driven by a CDL certified driver. The Contractor must provide Garage Keepers insurance if the chassis is hauled or driven. The contractor must have a secured (fenced, illuminated, lockable), parking area at its installation facility for up to forty (40) truck chassis.

2.2.2. The Contractor must inspect each truck chassis for damages within two (2) calendar days of receipt. The inspection must consist of a full visual inspection of the interior and exterior cab and exterior of the chassis; the Contractor is not required to disassemble any parts to complete the inspection; only to visually inspect the chassis without removal of parts.

2.2.3. The Contractor must provide written notification to ITD’s CMT within two (2) Business Days after receipt of the chassis. The Contractor must include in this notice if any damages were found. If damage is found, the Contractor must provide a detailed description of the damage to include photos with accurate date and time stamps of the damage. ITD’s CMT will be responsible for disputing damages to the chassis vendor and coordinating the chassis pick up for repairing the damages. The Contractor will not be responsible for any damages reported to ITD’s CMT within two (2) Business Days after receipt of the chassis. Any damages not reported to ITD’s CMT within two (2) Business Days after receipt of the chassis, will be the responsibility of the Contractor to correct, at no cost to ITD.

2.2.4. The Contractor must conduct a pre-delivery inspection of the completed Equipment prior to notifying ITD’s CMT that the Equipment is ready for inspection per Attachment 6 - Contract Management, Section 8.1. The Contractor’s inspection must be customized to reflect Equipment requirements, including but not limited to hydraulic system individual pressure settings, hydraulic controls operation, spreader control system operation, dump bed and tailgate operation, tarp system, warning lights, hydraulic hose and electrical wire routing and protection. Inspection results must be recorded on a pre-delivery inspection form, which must include the last eight (8) digits of the truck VINCH A copy of this inspection must be signed and dated by the technician performing the inspection, placed in a clear plastic paper sheet protector, and stowed in each truck chassis cabs.

2.2.5. The Contractor must notify ITD’s CMT upon completion of the Equipment, per the delivery schedule. The Contractor must schedule and coordinate the travel for ITD’s inspections of the completed Equipment per Section 3, below. No Equipment shall be delivered to ITD without an inspection and approval from ITD’s CMT.

2.2.6. The Contractor must deliver each truck chassis with the installed Equipment to ITD’s HQ location at 3311 West State Street, Boise, ID 83703. For the Contractor with an installation facility within a fifty (50) mile radius of the delivery location, the Contractor may drive the completed unit to the delivery location. For the Contractor with an installation facility beyond a fifty (50) mile radius, the Contractor must haul (not drive) and unload ITD’s truck chassis with the completed Equipment to the delivery location. The Equipment (except Pilot) must be delivered, at a minimum, five (5) each per month, once the lead-time is complete.

For example: An Order is placed on July 1st. The Contractor responds within 10 business days and identifies a required lead-time of 180 calendar days after receipt of the Order. The lead-time completion date is December 28th.The first group of five (5) truck chassis with installed Equipment must be delivered to ITD by January 31st. The second group of five (5) truck chassis with installed Equipment must be delivered to ITD by February 28th, and so forth until the Order is complete. For an Order of fifty (50) units, the Order would be delivered, in full, by October 31st.

2.2.7. All expenses related to delivering the truck chassis to the delivery location are the responsibility of the Contractor and must be included in its fully burdened cost. The Contractor must provide the necessary labor and equipment to unload the truck chassis with Equipment, including any re-assembly of Equipment components that were disassembled for delivery or unloading.

2.2.8. The Contractor must not operate ITD’s truck chassis on public right of ways at any time while in the Contractor’s custody, unless the Contractor received written permission from ITD’s CMT, or the Contractor is delivering the truck chassis with installed Equipment to ITD’s delivery location.

2.2.8.1. The Contractor must be in compliance with Section 13, Insurance Requirements, while the truck chassis are in the Contractor’s possession. If a subcontract is to perform the delivery, the Contractor must also comply with Administration Document, Section 12, Subcontracting.

2.2.8.2. The delivery driver must be in compliance with all state and federal requirements for operating the specific truck chassis and must have a valid commercial driver’s license.

2.2.9. The Contractor will be responsible for all fuel required to move the truck during installation of the specified equipment. Contractor will be responsible for all fuel needed to deliver the truck to the delivery location and the truck must be full of fuel when delivered. Contractor shall utilize a winter blend fuel (60% number 2 diesel, 40% number one diesel) in any supplied chassis when the chassis is in the Contractors possession between November 1, to April 1, of the following calendar year.

Travel for Inspections 1.

2.

3.

3.1. The Contractor is responsible for all costs associated with all inspections, as detailed in Attachment 6-Contract Management, Section 8.1, for all inspection locations beyond fifty (50) miles of the delivery location. Travel will be for three (3) ITD employees and Contractor personnel, and must include travel, lodging, and meals. A minimum of one contractor must accompany the ITD employees. This includes all costs for repeat travel due to any Discrepancies found during the inspections. All costs must be included in the fully burdened bid price.

3.2. To prevent overtime cost for ITD employees traveling, all flights must be reserved during Business Days/Hours. Every effort must be made by the Contractor to ensure flights are booked to make the most direct flight possible.

Pilot 1.

2.

3.

4.

4.1. Pilot is the first Equipment to be built and assembled from the first Order of the Contract. There will be multiple inspections for the Pilot as detailed in Attachment 6 - Contract Management, Section 8.1. The Pilot must be ready for the initial inspection within sixty (60) calendar days after completion of the lead-time for Pilot. The Pilot may remain in the possession of the Contractor after the Final Assembly Inspection to use as a model for subsequent units. Payment for the Pilot will not be made until delivered, and the Final Delivery Inspection is complete, and the unit is accepted by ITD.

4.2. Pilot Inspections –

4.2.1. The purpose of the Pilot Inspection is 1) to ensure the first unit built is in compliance with the Contract, 2) to identify Discrepancies early in the build process to avoid major overhaul at the end of the process, and 3) to provide an example unit from which all other units should be built.

4.2.2. The Pilot Inspection will consist of three (3) initial inspections, one (1) final assembly inspection, and any repeat inspections due to Discrepancies. Building the Equipment specified in the initial inspections may occur at the same time. However, the final assembly must not occur until the Contractor has received written approval from ITD.

4.2.3. The Contractor must be present for each inspection detailed below.

4.2.4. The initial inspections will consist of the following (the Contractor may elect to have ITD conduct additional inspections, at different points in the build process, beyond what is listed below):

· Build and install one (1) Hydraulic System and Snowplow Components and stage one (1) passenger side 8 ft. Extendable Truck Mounted Wing Plow. Inspection to be conducted at the Contractor’s facility.

· Build and stage the 10 CY Asphalt Dump Body. Inspection to be conducted at the manufacturer’s facility.

· Build and stage the 8 CY V-Box Spreader. Inspection to be conducted at the manufacturer’s facility.

4.2.5. The final assembly inspection will consist of the following:

· The fully installed and assembled Equipment listed above. Inspection to be conducted at the Contractor’s facility.

4.3. Monthly Inspections

4.3.1. The purpose of the Monthly Inspection is: 1) to ensure each group of units built (per the delivery schedule) are in compliance with the Contract, 2) to identify Discrepancies prior to delivery to ITD, and 3) to eliminate, as much as possible, repeat deliveries for failed inspections at the delivery location.

4.3.2. The Monthly Inspection will consist of one (1) inspection, with any repeat inspections due to Discrepancies, at the Contractor’s facility. Delivery to ITD must not occur until the Contractor has received written approval from ITD.

4.3.3. The Contractor must be present for this inspection.

4.4. Final Delivery Inspection

4.4.1. The purpose of the Final Delivery Inspection is 1) to ensure the Equipment is in compliance with the Contract, and 2) to identify Discrepancies that may have missed during the Pilot Inspection and Monthly Inspections.

4.4.2. Acceptance will not occur until the ITD has completed the Final Delivery Inspection and ensured that the Equipment is in compliance with the Contract.

4.4.3. The Final Delivery Inspection will take place at ITD’s delivery location.

4.5. Inspection Results & Acceptance

4.5.1. During each inspection, the Equipment will be inspected by ITD for compliance with the Contract. Following the inspection, ITD will send an email notice to the Contractor within ten (10) Business Days to: 1) accept the Equipment as being compliant with the Contract, or 2) reject the Equipment and identify all Discrepancies that require corrective action.

4.5.2. If the notice is of rejection, the Contractor must provide an email response acknowledging the Discrepancy(ies) and providing an estimated time for corrective action. All Discrepancies must be corrected within seven (7) calendar days after receipt of the notice from ITD.

4.5.3. For Pilot & Monthly Inspections – If the notice is of approval, the Contractor shall proceed with the next step as directed by ITD (i.e., pilot’s initial inspection approval will lead to final assembly, and monthly inspection approvals will lead to delivery to ITD for final inspection).

4.5.4. For Final Delivery Inspections – If the notice is of Acceptance, the Contractor shall proceed with the invoice procedures outlined below.

Wing Installation 5.

5.1. All new wing configurations must be inspected and approved by ITD prior to completing the installation. Pilot will consist of one type of wing configuration, thus will be inspected during the Pilot Inspection. All other wing configurations must be inspected and approved by ITD during the Monthly Inspections. Upon arrival, ITD will inspect the units that are ready for delivery. Then, ITD will inspect the wing installation on any units in progress that have a new wing configuration.

Manuals 6.

6.1. The Contractor must provide the following items at the time of delivery. Stated items must cover all systems to include drawings, schematics, applicable technical information, and component parts including the hydraulic lift cylinder, air tailgate cylinder, electrical junction box, electrical wire magnetic plug, warning sensors, dump body, dump body components, and wing plow and components.

6.1.1. One (1) service manual per Equipment – PDF format.

6.1.2. One (1) parts manual per Equipment – PDF format.

6.1.2.1. Make and Model of all installed components.

6.1.2.2. Complete, fully illustrated parts listing for all Contractor installed components.

6.1.2.3. Each add-on electrical accessory circuit must have its own circuit diagram, showing the complete power and ground sides, routing, wire color and gauge, pin numbers, switches, breaker, or fuse location and/or number, and specific ground point locations.

Warranty 7.

7.1. The Equipment, including all accessories, must be warranted against all defects in material and workmanship (including paint and varnish sealant defects) by either the manufacturer or the Contractor for a period of no less than one (1) year, with exception to the 10 CY Asphalt Dump Bodies, 10 CY Rock Bodies, telescopic hoists, and air tailgate cylinders, which must be warranted for a period of no less than five (5) years.

7.2. Warranty must include all travel, parts, labor, and freight to replace a defective warranted item. All warranty work must be completed within thirty (30) calendar days after receipt of notice from ITD.

7.3. If any warranty work is to be performed, the Contractor may elect to authorize a dealer of its choice or authorize ITD to perform the necessary repairs in accordance with the manufacturer’s standards. If the Contractor authorizes ITD to perform any warranty work, it is the responsibility of the Contractor to guarantee that the work is completed in accordance with the manufacturer’s standards at the expense of the Contractor. Completion of warranty repairs by ITD which are authorized by the Contractor will not adversely affect the warranty.

7.4. The Contractor will be allowed to operate ITD’s truck on public right of ways when performing warranty repairs to validate the warranty issued has been addressed.

7.5. Warranty must commence when completed Equipment is placed into service. “In-Service” date is defined as the date the completed truck chassis passes final delivery inspection with all Equipment installed and operational. ITD’s CMT will be responsible for reporting “In-Service” dates to the Contractor.

7.6. Documentation - Warranty documentation and an acceptance letter agreeing to the special warranty provisions of the Equipment outlined above must be submitted with bid response.

Training 8.

8.1. The Contractor must provide a manufacturer authorized service representative(s), knowledgeable of the installed Equipment, to give instructions on the operations, maintenance, and safety of the Equipment for approximately ten (10) to fifteen (15) ITD personnel per training session. The representative (s) must be versed in all aspects of the truck. At a minimum, training must include:

8.1.1. Introduction to the installed Equipment, hydraulic system pre-operations check (including fluids, start-up, shutdown), hydraulic controls pre-operation check (including joystick, spreader controls, start up, operation of the wing, warning lights, system warning light’s location, light identification, description, safety features and hydraulic system shutdown), and hydraulic controls calibration.

8.2. The Contractor must provide two (2) training sessions per Order. Session 1 must be occurred upon delivery of the first ten (10) units. Session 2 must occur upon delivery of the last group of units. Payment of the last unit, per Order, will be withheld and not paid until both training sessions have been performed and accepted by ITD’s CMT.

8.3. Each training session will be four (4) to six (6) hours as detailed below. ITD will be responsible for coordinating and scheduling the manufacturer representatives for all equipment not specified in this Contract. The Contractor will be responsible for coordinating and scheduling the manufacturer representatives for all Equipment specified in this Contract.

8.3.1. One (1) hour for the truck chassis manufacturer or dealer

8.3.2. One (1) hour for the transmission manufacturer

8.3.3. One (1) hour for the dump body manufacturer or installer

8.3.4. One (1) hour for the hydraulic/spreader control manufacturer

8.3.5. One (1) hour for the wing manufacturer

8.3.6. One (1) hour for the spreader/liquid deicer manufacturer

8.4. Each training session must occur at ITD’s destination. This destination is not the same as the delivery location made to ITD. The training will occur at each of the six (6) ITD districts throughout the state. The training location will be provided with each Order. All costs associated with training must be included in the fully burdened bid price.

Model & Assembly 9.

9.1. The Equipment must be the latest model of the manufacturer's current standard production, as offered to commercial trade. Though they are not specifically covered herein, all parts necessary to provide complete and functional Equipment must be furnished. All parts must conform in design, strength, quality of materials, and workmanship to current engineering practices and accepted standards of the industry. All parts must be the manufacturer’s standard unless otherwise specified in this ITB.

9.2. The Equipment must be assembled and adjusted when delivered. All Equipment, including standard and supplemental equipment, must be installed per the manufacturer’s specifications, serviced and ready for continuous operation at the time of delivery, unless otherwise stated in this ITB. The entire truck chassis with installed Equipment must be cleaned prior to delivery.

9.2.1. The Equipment will be mounted on an ITD tandem rear axle truck chassis equipped with an Allison automatic transmission and a REPTO.

9.2.2. Trucks will be used for material hauling, trailer towing, and operation of hydraulically controlled snowplows and material spreaders. The 10 CY Asphalt Dump Bodies and hydraulic systems described in these specifications will be designed for dump truck and snowplow/anti-ice/v-box spreader applications.

9.3. Equipment must be installed by a Contractor actively engaged in the installation of truck chassis Equipment and the installation, calibration, customization, diagnostic and troubleshooting of hydraulic systems, digital liquid/material dispensing spreader controls, digital snowplow joystick controls, GPS and digital data recording and Wi-Fi drive-by download equipment and all other associated truck chassis auxiliary snow and ice components. Assembly must be performed in a manner to promote ease of maintenance.

Serial Numbers 10.

10.1. 10 CY Asphalt Dump Bodies, Rock Bodies, hoists, hydraulic enclosures, snowplow harnesses, wing plows, V-box spreaders, and slide-in deice tanks are required to have independent serial numbers documented and provided to ITD’s CMT, by the Contractor, at time of delivery, corresponding to each truck chassis number that the component it is installed on. This provides ease in tracking and documenting component warranty and replacement parts.

Welding 11.

11.1. All welds on the 10 CY asphalt dump bodies, Rock bodies, snowplow harnesses, eight (8) ft. and ten (10) ft. wing plows, V-box spreaders, and deice tanks must meet the AWS D1.1-96 specifications. All Joints and seems must be closed with full seam welding.

Steel 12.

12.1. Steel, and stainless-steel certifications for all components must be supplied to ITD’s CMT at the time of the Pilot Inspection.

Hydraulic Installation 13.

13.1. All hoses must be high pressure type, including return lines.

13.2. All hoses must be routed in a manner to minimize rub points and bends. Hoses that will rub against metal during the operation of the Equipment must be wrapped for protection.

13.3. All hoses must be routed to protect them from heat sources and enclosed whenever possible to protect them from damage.

13.4. Teflon tape must not be used in the hydraulic system.

13.5. Hydraulic hoses must not be secured to any factory-installed chassis wiring, cables, hoses, or lines.

13.6. Hydraulic hoses must not be secured in the same bundle with any electrical wiring.

13.7. Hoses must be supported and securely fastened every twelve (12) inches with hose blocks, to withstand snow and ice conditions, unless otherwise approved by ITD’s CMT,

13.8. Hoses must be supported and securely fastened to withstand snow and ice conditions.

13.9. Hydraulic components and fittings must be sealed during assembly to prevent system contamination.

13.10. Hose interior must be cleaned prior to installation.

13.11. All hoses must be separated when routed and secured with hose blocks. Bundling of hoses is not acceptable.

Electrical Installation 14.

14.1. All installed electrical cabling must be of adequate size to handle the anticipated loads of all electrical components. All cabling must be uninterrupted and complete with no splices.

14.2. All electrical cabling must be color-coded or numbered.

14.3. All cable terminal ends must be crimped, soldered to the cables, and sealed with polyolefin heat shrink tubing, or weatherproof connectors. Scotch-Loc fasteners and/or crimp butt connectors are not acceptable for any connection.

14.4. Three (3) wires soldered together is not acceptable.

14.5. All electrical cable connections must be protected with dielectric grease.

14.6. All exposed electrical cabling must be enclosed in a conduit, wrapped harness including CAN bus communication cables and be grommet protected when passing through metal or sharp surfaces. Split loom not acceptable.

14.7. All wiring must be clamped and held in place using stainless steel rubber-insulated, bolt-on clamps.

14.8. All wiring passing through bulkheads and/or skid assembly components must be protected with either rubber or neoprene bulkhead wire protectors and/or body grommet type insert.

14.9. All electrical cabling to lamps must be stress relieved within six (6) inch of the lamp.

14.10. Low current circuits must be controlled by the truck chassis’ electrical accessory power supply.

14.11. All wiring used in and around the truck cab must be automotive cross link wiring meeting SAE specification J1128 or J1127 for under the hood temperatures and abrasion resistance. All electrical modifications and/or additions must require the use of continuously numbered or same colored wiring and the same wire gauges (size) as the manufacturers wiring.

14.12. All exposed wiring soldered and sealed with polyolefin heat shrink tubing. Crimp-on connections are not acceptable.

14.13. Exposed terminal connections must be coated with Permatex SA-9 battery protector and sealer.

14.14. An electrical schematic must be provided to ITD’s CMT during the Pilot Inspection. All consecutive truck builds must follow this schematic.

Fasteners 15.

15.1. All threaded fastener components (bolts, washers, nuts) with a diameter designation greater than or equal to SAE one half (1/2) inch must be grade eight (8). All nuts must be metal self-locking; lock washers are not acceptable. All bolts must be properly tightened/torqued per manufacturer’s specification. All components must have grade identifier marks. All bolts and nuts must be zinc plated.

Alignment 16.

16.1. Contractor must ensure a three (3) axle center thrust alignment is completed on each truck chassis after installation of the Equipment prior to delivery to ITD. This is to ensure that the axles and wheels are set to the truck manufacturer’s specifications, to improve drivability and to prolong tire life. Wheel alignment must be performed by a company that is actively engaged in performing wheel alignment on trucks equipped with three (3) or more axles. Documentation stating the before and after alignment settings must be inserted in a clear paper sheet protector and placed in the truck chassis cab overhead storage bin upon delivery to ITD for Final Delivery Inspection.

Paint 17.

17.1. Paint is not required on stainless steel components.

17.2. All visible finishes must be smooth, shiny, and free of runs, overspray, weld splatter, and other defects.

17.3. All mild steel components must be cleaned and completely painted the color and procedure designated within the specifications, below.

SECTION 2: ITEM 1 - HYDRAULIC SYSTEM AND SNOWPLOW COMPONENTS

1. Snowplow Harness

1.1. ITD Drawing – Attachment A & B Drawing, is provided to show and demonstrate the overall design of the ITD snowplow truck harness. The drawings are not to be considered inclusive.

1.2. Contractor Drawing - At the kickoff meeting, the Contractor must provide a full set of shop drawings of the harness and related components they intend to provide and install as part of this Contract. Those drawings must be approved by ITD prior to construction of the Pilot.

1.3. Installation – Contractor must install the harness on the ITD supplied truck chassis. The installation process must include cutting the truck front frame extension to a length determined and approved by ITD.

1.4. Front Bumper – Must be swept back on drivers and passenger side. Exact installation placement must be approved by ITD prior to installation

1.5. Material – All material must be ASTM A-36 steel unless otherwise specified on the list-out sheet of the attached drawings.

1.6. Color – Each snowplow harness must be prime coated with a 2-part urethane epoxy coating sprayed to a dry thickness of three (3) mils. Topcoat paint must be a two-part polyurethane high gloss black sprayed to a dry thickness of three (3) mils. Black powder coat finish is acceptable.

1.7. Plow Hydraulic Lift Ram

1.7.1. Barrel – Minimum four and three hundred seventy fifths (4.375) inside diameter (ID) DOM tubing and nitride plated for corrosion protection.

1.7.1.1. Rod End – Screw-on collar secured with one fourth (1/4) inch set screw.

1.7.1.2. Blind End – one half (1/2) inch thick steel.

1.7.2. Rod – four (4) inch hollow nitride tubing.

1.7.3. Stroke – ten (10) inches.

1.7.4. Retracted Length – twenty-four (24) inches.

1.7.5. Rating – three thousand (3,000) PSI

1.7.6. Blind End – two and one half (2-1/2) inch x one and one half (1-1/2) inch with a one and one sixty fourth (1-1/64) inch hole centered one (1) inch from the cylinder end.

1.7.7. Rod End – Type R2, two and one half (2-1/2) inch x one and one half (1-1/2) inch with a one and one sixty fourth (1-1/64) inch hole centered one (1) inch from the end.

Hydraulics and Hydraulic Control System

1.

2.

2.1. Description - The integrated Certified Power Solutions (CPS) hydraulic system must power, control and log data for spreader and joystick functions. Closed loop spreader data and joystick data must be transmitted in a format compatible with ITD’s existing Winter Automated Reporting System (WARS) via Wi-Fi connection through Certified Power Solutions GPS DataSmartTM into the ITD WARS program.

2.2. The hydraulic system must include the following Certified Power Solutions components: CPS SpreadSmart RxTM spreader control, CPS MAKO-IITM joystick control, CPS PowerSmartTM power distribution control, CPS Moray Jr.TM power float, CPS Danfoss Manifold/PVG32 valve assembly, CPS BTC stainless steel enclosure, CPS BTC Stainless Steel reservoir, Danfoss S45 100cc load sense pump and all cables and sensors required to deliver the ITD WARS format data se.

2.3. Complete System Part Number: CPS HYD-2022-WARS-10 CY-Tab/Cam-Tandem.

Hydraulic and Control System Components and Requirements

1.

3.

3.1. Pump Drive - From REPTO, tubular-shaft and splined.

3.1.1. Drive Line – two (2) inch x one hundred twenty ten-thousandths (0.120) inch wall tubular driveshaft utilizing Spicer 1310 series slip joint and tube yoke. Pump shaft must be drilled and tapped to accept a mounting bolt securing the flange to the pump in addition to set screw.

3.1.2. All driveshaft installation hardware must be to driveline manufacturer’s specifications.

3.1.3. Completed driveshaft assembly must be balanced prior to being installed on truck and hydraulic pump.

3.1.4. Driveline Shield – Removable safety shield over the exposed section of driveshaft (hydraulic pump connection) to protect against injury while running. Shield must be Stainless Steel with applied safety label.

3.2. Pump and Fittings.

3.2.1. Suction Fitting – Flanged, formed elbow hose barb. Fitting must be of adequate size for the displacement of the pump.

3.2.2. Case Drain – Positioned as high as possible and directed back to the hydraulic reservoir without passing through the return line filter. Pump must be equipped with multiple drain ports to allow for multiple mounting orientations.

3.2.3. Discharge Fitting – O-ring thread flange block. Fitting must be sized to the displacement of the pump.

3.2.4. Performance Check – System standby pressure must be set at four hundred fifty (450) PSI. System main pressure must be set at two thousand six hundred fifty (2,650) PSI. Pressures to be set by the pressure gauge inside the valve enclosure. Pressures to be set when hydraulic oil is at operating temperature.

3.3. Hydraulic Reservoir

3.3.

3.3.1. Type – Stainless steel reservoir must be of the upright design forty-two (42) gal Mounted on top of the frame rails positioned between the truck chassis cab and asphalt dump body and to the right (passenger side). Stainless steel reservoir to include an in-tank ten (10)-micron filter assembly with electric filter bypass sensor and a top mount temperature/level electric sensor. Reservoir must be full at time of delivery.

3.3.2. Reservoir must be installed across the truck chassis frame rails. A two and one half in brass ball valve to be installed under reservoir tank on suction line. Valve to have three fourths (3/4)-inch zip tie keeping valve in the open position

3.3.3. Mounting Hardware – Reservoir must be complete with all mounting hardware; frame mounting angles, bolts with poly locknuts, and springs.

3.3.4. Oil Sample Fitting - Titan Laboratories Model OD1014, installed between sectional manifold and return filter housing in hydraulic oil return line.

3.4. Hydraulic Valve Enclosure

1.

3.

3.1.

3.2.

3.3.

3.4.

3.4.1. Type – Stainless steel valve enclosure must be of the upright vertical design and mounted on top of the frame rails positioned between the truck chassis cab and asphalt dump body beside the hydraulic tank, on the driver’s side of the chassis.

3.4.2. Enclosure door to be made of aluminum and will be lift off type utilizing three (3) handles. The door will have rubber tension clamps for closure. All edges including handles must be buffed smooth. Sharp edges are unacceptable. The hydraulic hoses and fitting must exit the enclosure at the rear of the enclosure. Enclosure door to be constructed of aluminum.

3.4.3. Mounting Hardware – Enclosure must be complete with all mounting hardware; frame mounting angles, bolts with poly locknuts, and springs.

1.

3.

3.1.

3.2.

3.3.

3.4.

3.5. Hydraulic Hoses

3.5.1. Type – High pressure hydraulic hose meeting SAE 100R2 specifications. Includes return lines

3.5.2. Snowplow Lift and Angle Hoses – three eights (3/8) inch, must be supplied to snowplow harness and mounted on a bolt-on removable stationary bracket constructed of Grade 304 stainless steel mounted on truck front bumper. Snowplow lift hose must be equipped with a quick coupler with dust plugs/caps. Snowplow angle hoses must be equipped with one (1) male and one (1) female quick coupler with dust caps/plugs.

3.5.3. Labels – Each plow hose must be identified with an engraved label. Labels must be affixed to the snowplow hose bracket.

3.5.4. Snowplow hoses running from the hydraulic valve to the connection point at the front bumper must be separated with hose blocks, every twenty (20) inches unless otherwise approved by ITD’s CMT. Hoses must not hang down lower than the front axle or touch any part of engine or transmission. Tying the hoses together in a bundle with plastic tie retainers is not acceptable.

3.5.5. Dump Body Hoist hose– one (1) inch high pressure.

3.5.6. Dump Body Shut Off Valve – 1 in GE2-16 NPT high pressure hydraulic ball valve, Gemels model GE2NNT53011A000 or equal, with quick coupler and dust caps/plugs.

3.5.7. Mounting – Ball valve to be installed in dump body lift cylinder hydraulic line after the valve body. Location of Dump body Shut off Valve, Drivers side, behind fuel filter, easily accessible.

3.5.8. Spreader Circuits – Must be sized and supplied with quick couplers as described below:

3.5.8.1. Auger – three fourths (3/4) inch hose equipped with a female quick coupler and dust plug/cap.

3.5.8.2. Spinner – three fourths (3/4) inch hose equipped with a male quick coupler and dust cap/plug.

3.5.8.3. Pre-wet Hose – one half (1/2) inch hose equipped with a female quick coupler and dust plug/cap.

3.5.8.4. Accessory – one half (1/2) inch hose equipped with a male quick coupler and dust cap/plug.

3.5.8.5. Spreader Return Line – one (1) inch hose, High pressure, equipped with a female quick coupler and dust plug/cap.

3.5.9. Spreader Circuit Mounting Plate – Short hydraulic lead hoses are required to provide hydraulic valve connections without removing the protective valve enclosure cover. The lead hoses must be connected to a Stainless-Steel mounting plate located outside the hydraulic valve enclosure.

3.5.9.1. Mounting plate must be a grade 304 stainless steel removable bolt-on type.

3.5.9.2. Mounting plate must incorporate bulkhead fittings for hose and quick coupler connections.

3.5.9.3. Lead hoses must be connected to the mounting plate using JIC thirty seven degree (37°) Female Swivel sweeping ninety degree (90°) Tube Elbow hose ends.

3.5.9.4. Layout of hydraulic, electrical connections, and the location of the mounting plate, must be approved by ITD at time of the Pilot Inspection.

3.5.10. Labels – Each snowplow and spreader hose must be identified with an engraved label. Labels must be affixed to the snowplow hose bracket and spreader circuit mounting plate.

3.5.11. Protective Hose Sleeves/Guards – Must be included on all hoses for areas with potential wear spots. In areas where routing by heat sources, orange fireproof sleeve must be used. Sleeves to be held in place by a minimum of two (2) stainless steel hose clamps.

3.5.12. Fittings – Must be JIC type for all hoses.

3.5.13. Requirement – Hydraulic hoses must not be secured in the same bundle with any electrical wiring.

3.6. Assembly of Hydraulic Components

3.6.1. All components and fittings must be sealed during assembly to prevent system contamination.

3.6.2. Hoses – Hose interior must be cleaned prior to installation.

3.6.3. Painting – Hydraulic hoses, valves, and components must be washed, painted if constructed of steel, and free of oil film prior to delivery.

3.7. Hydraulic Valve Drivers - Material control system (spreader/pre-wet/anti-ice) hydraulic valve drivers must be in a safe, protected area, inside the truck chassis’ operators cab or inside the hydraulic valve enclosure. Valve driver components must be installed to be removable for service and/or replacement if required.

3.7.1. Bulkhead connectors must be used in lieu of rubber grommets when installing wiring cable.

3.8. Joystick Mounting - Must be mounted to the right side of the truck chassis operator seat utilizing an integrated padded arm rest (Armrest) and control console. Joystick is required to move up/down/fore/aft with corresponding movement of the operator's seat.

3.9. Spreader Controller Speed Sensor – System must connect to the truck chassis automatic ECU control unit.

3.9.1. Analog to digital signal converter, if required, for making a complete and working unit.

3.9.2. Connecting to the truck chassis ECM for a speed signal is not acceptable.

3.10. Spreader Controller Mounting

3.10.1. The spreader control system’s display screen must be dash mounted with aluminum support brackets. Contractor is responsible for providing reinforcing plates behind dash. Screen must face towards driver and be adjustable up/down/left/right, for optimum viewing.

3.10.2. Using sheet metal/wood screws into plastic is unacceptable.

3.10.3. The keypad and joystick must be installed in the Armrest padded armrest mount. The Armrest must be seat mounted, driver’s seat, and right side, replacing the factory OEM installed armrest. The armrest must include an additional custom fabricated front mount to assist in the support of the weight when attached to the seat back. The Armrest must move up/down/forward/back with the movement of the seat. The Armrest must not come into contact with any other truck controls when the seat is adjusted to the maximum cab forward position.

3.11. Wi-Fi Communication Components – Truck mounted wireless bridge and antenna. Location of bridge must be on truck chassis’ cab rear (back) window, center of window.

3.12. System Testing / Calibration –

3.12.1. Hydraulic Spreader Control System – All hydraulic function controls must be calibrated for proper operation before inspection and delivery of completed truck.

3.12.2. Material Application Equipment – ITD will be responsible for the calibration of granular application, granular pre-wet system, and anti-liquid application on its snow and ice Equipment.

3.13. Blade Save Valve(s) – Mounted inside the hydraulic valve enclosure.

3.14. Electronics Cabinet Location – Bolted to floor on an elevated bracket, against the truck chassis’ cab back wall, located between the driver and passenger seats. Offset towards passenger seat so that when the armrest is swung out, and seat lowered, armrest doesn’t hit the cabinet. Must include a support brace between the cabinet and cab back wall, if required, to eliminate excess vibration/movement, and possible premature metal fatigue of the cabinet.

3.15. Auxiliary Fuse Block –

3.15.1. Located inside of the Cirus Electronics cabinet.

3.15.2. Key activated for both run and auxiliary key positions using seventy-five (75)-amp relay. Circuit protected with eighty (80)-amp self-setting circuit breaker.

3.15.2.1. Relay must be seventy-five (75)-amp rated with a resister in parallel to the coil to limit EMI and;

3.15.2.2. Circuit breaker must be water resistant

3.15.3. Individual fused circuit and ground connections to provide power for:

3.15.3.1. Hydraulic joystick control, ten (10)-amp maximum circuit

3.15.3.2. Material controller, twenty-five (25) amp maximum circuit

3.15.3.3. State communication radio, twenty-five (25) amp maximum circuit.

3.15.3.4. Two (2) spare circuits.

3.15.4. Ground Cable – Electronic cabinet must be directly grounded to truck batteries, and battery connections coated with anti-corrosion paint after installation.

Lighting/Wiring

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4.1. Requirement – Compliant with all State of Idaho transportation requirements and FMVSS.

4.2. Auxiliary Trailer Connector – Truck chassis manufacturer will provide either a seven (7)-wire harness or electrical connection module at the rear of the truck chassis cab for connecting asphalt dump body mounted clearance and stop/turn/taillights, and auxiliary warning lights.

4.3. Switch Panel(s) – The truck chassis manufacturer provides auxiliary switches which include ignition and battery powered switches. The switches must be used to control the ITD specified auxiliary work lights and emergency warning lights. Cable from the switches terminates at the rear of the truck chassis cab.

4.4. Lighting Electrical Connection – Install and complete the connection of the auxiliary trailer connector and switch panel circuits to one (1) EZ- Connector female connector socket making all systems operational utilizing a Betts P/N 351044 junction box. One (1) EZ-Connector P/N S14-05 with self-closing plug holder on a Contractor supplied bracket located at the rear of the truck chassis cab on driver’s side. Location to be determined at pre-build meeting.

4.4.1. EZ- Connectors are molded, completely sealed from moisture and the environment. Cable length can be custom ordered to minimize cable splicing during installation. It is the Contractor’s responsibility to order the required correct cable length for the plug connectors.

4.5. Electrical Cable Connections – Install and complete the connection of the electrical cables to the EZ-Connector socket making all systems operational.

4.5.1. White – Dump body mounted lights ground.

4.5.2. Black – Two (2) Top mounted warning lights to be activated with Smartplex switch labeled Strobe, in cab. Not to be connected to the Whelen Core-R system.

4.5.3. Red - Stop lights from truck chassis.

4.5.4. Green - Right turn signal and hazard signal lights from truck chassis.

4.5.5. Orange – Left turn signal and hazard signal lights from truck chassis.

4.5.6. Blue – Tail/Marker lights from truck chassis.

4.5.7. White/Black – Spreader mounted lights ground.

4.5.8. Red/Black – Tailgate from truck chassis.

4.5.9. Green/Black – Left rear dump body warning light drivers side rear four hundred (400) amber

4.5.9.1. Output 1 on the WCX Expansion Module. Controls the driver side rear four hundred (400) amber

4.5.10. Orange/Black – Right rear dump body warning light passenger side rear four hundred (400) amber.

4.5.10.1. Output 2 on the WCX Expansion Module, Controls the passenger side four hundred (400) amber.

4.5.11. Blue/Black – Amber alternating lights on sander from WCX Expansion Module.

4.5.12. Black/White – Red alternating lights from WCX Expansion Module.

4.5.13. Red/White – Load/Tank light from truck chassis.

4.5.14. Green/White – Spinner/Distributor light from truck chassis.

4.6. Warning Lights Flasher – Whelen Smart Logic Programmable system, 16 output WCX expansion module, Vehicle to Vehicle sync module and photo eye, mounted in truck cab. Mounting location to be determined during pilot inspection. Some chassis mounted warning light switches are the inputs to the flasher for the dump body warning lights, sander, or deicer tank alternating lights. The “Inputs” and “Outputs” must be wired as follows:

4.6.1. CORE – R Input 1 - Rear Flasher Switch

4.6.2. CORE – R Input 2 – Rear Alternating Light Switch

4.6.3. CORE – R Input 3 – Wing Plow Light Switch

4.6.4. CORE – R Input 4 – Brake Signal

4.6.5. CORE – R Input 5 – Reverse Signal

4.6.6. CORE – R Input 6 – Photocell input

4.6.7. CEM16 Input 1 – Right Turn Signal

4.6.8. CEM16 Input 2 – Left Turn Signal

4.6.9. Output 1 – Driver side four hundred (400) amber (See D.5.i above)

4.6.10. Output 2 – Passenger side four hundred (400) amber, (See D.5.j above)

4.6.11. Output 3 – WIONSMA mounted on drivers' side of the front grill

4.6.12. Output 4 – WIONSMA mounted on passenger side of the front grill

4.6.13. Output 5 – Red alternating lights (See D.5.l above)

4.6.14. Output 6 – Amber alternating lights (See D.5.k above)

4.6.15. Output 7 – Wing Plow light #1 (Amber)

4.6.16. Output 8 – Wing Plow light #2 (Amber)

4.6.17. Output 9 – Wing Plow light #3 (Amber)

4.6.18. Output 10 – Wing Plow light #4 (Red)

4.6.19. Output 11 – Wing Plow light #5 (Amber)

4.7. All perimeter warning light heads (on dump body, spreader, deicer, wing, and grill) must be set to a steady burn pattern before connecting to the Whelen control system to insure proper operation. This does not apply to the top mount light bars as they will have an on-off signal from the vehicles “Strobe” switch.

4.8. Before delivery, the CORE – R system in each vehicle should be programed with the provided “ITD CORE – R Config” file which includes the desired flash patterns and functionality of ITD.

4.9. Spreader Sensor Feedback and Anti-Ice Cabling and Connections – Install and mount the Certified Power Solutions Feedback Connection cable to bulkhead fittings mounted to the Contractor supplied electrical cable connector bracket located at the rear of the truck chassis cab on the driver side.

4.10. Driving Lights – Two (2) halogen or two (2) heated LED lights, mounted on stainless steel support brackets mounted to chassis provided four (4)-post fender mirror brackets with the center of the lights mounted seventy-two (72) inches above the ground. Lights must be approved by ITD at pre-build meeting.

4.11. Snowplow Lights – Two (2), Ecco EW4010 heated LED Snowplow lamps mounted to the front of the truck chassis’ tilting hood on the same stainless-steel brackets as the driving lights, with the center of the lights mounted seventy-two (72) inches above the ground. Lights must be mounted outside of the driving lights. Contractor will be responsible for providing required wiring from dash/overhead mounted switch to the heating element of the snowplow lights and making all connections.

4.12. Driving lights and snowplow lights must be manually controlled by switch supplied by the truck chassis manufacturer. Installation must include Weather Pac quick disconnect electrical plugs for easy removal of the lights. All light pigtails must be wrapped with Ico-Rally flexible woven polter fabric Model No. 22490.

4.13. Light Mount Hood Bracket – Bracket must be constructed of stainless steel and mounted to chassis provided 4-post fender mirror mounts with a minimum of three (3) mounting points.

4.14. Grill Mounted Warning Lights - Two (2) Whelen model IONA, amber lights. Lights must be horizontally installed inside front grill, forward facing, as high inside grill as possible, each spaced as far apart as possible. Lights must be installed level with each other in the same row on the grill. Grill mounted lights must be wired to the Core-R system (See D.6 above), Outputs 1 and 2.

4.15. Chassis Mounted Stop/Turn/Taillights – Two (2) Truck-Lite LED Model 60 - No. 60085R lights, for combination stop/turn/taillights.

4.15.1. Light heads for combination stop/turn/taillights must be mounted outside of the truck chassis’ rear hitch plate in the 3 inch recessed space provided.

4.16. Identification Bar – Truck-Lite LED Model 15 - No. 15050R.

4.16.1. Identification bar must be located on the rear of the truck chassis, above the rear hitch plate, and fastened to the dump body hinge block in between the two (2) asphalt dump body hinge pins.

4.17. License plate Lamp – Truck-Lite LED Model 15- No. 15041.

4.17.1. License plate lamp and license plate must be mounted to truck chassis’ rear hitch plate.

4.18. Backup Light – Maxxima LED Model No. M63318, must be mounted to the truck chassis’ rear hitch plate, centered as high on the hitch plate as the hinge block will allow.

4.19. Work Lights – Two (2), Whelen Micro Pioneer high output amber LED (twelve (12) Super LEDs with TIR reflector), square aluminum housing, flood beam work lights must be installed for the side mounted wing plow. Interchangeable lenses (clear/amber) must be placed inside cab for driver preference.

4.19.1. One (1) work light must be located forward under truck chassis cab top step, the second light mounted under dump body behind wing post. Front work light must be aimed at the face of the wing plow with the wing plow deployed. The Contractor must connect work lights utilizing the truck chassis Smartplex switch labeled “Wing Lights”.

4.20. Reverse Warning Alarm – 300 Series Preco-matic self-adjusting mounted behind butt plate.

10 CY Dump Body Hinge Block/Hitch Plate

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5.1. Hinge block and hitch plate components must be constructed of high tensile strength steel, sixty-five thousand (65,000) PSI, unless otherwise stated in these specifications.

5.2. 10 CY Dump Body Rear Hinge Block – Attached to truck chassis frame with asphalt dump body hinge pin aligned with rear edge of rear truck chassis tire. Hinge block to be equipped with either grease zerks or greaseless composite bushings.

5.2.1. Longitudinal – Truck frame rail beams must line up with the hinge blocks.

5.2.2. Hinge Pins – Stainless steel two (2)-piece design, must have the capability of removing pins either inward or outwards.

5.3. Hitch Plate – one half (1/2) inch thick plate steel for mounting pintle hook hitch and safety chain D-rings.