DRAFT_MCV_PD_03.24.2014.pdf

DRAFT

03.24.2014

Purchase Description

Mobile Communications Vehicle (MCV)

Note to Offeror: Offeror shall explicitly and completely identify any and all exceptions taken to the requirements of this specification in accordance to the instructions in the solicitation. Drawings, literature, and any other information submitted with an offer do not constitute a stated or implied exception unless specifically identified in writing as an exception and accepted and implemented by an amendment to the solicitation or modification to a contract. Any exception deemed acceptable by the Government shall only apply to the specific item, requirement, etc. cited, and shall not extend to any other requirement.

Offeror offering other than brand name items identified below, when an “or equal” may be acceptable, shall furnish with their offers all technical data information, product descriptions, etc. to ensure that a determination may be made as to the equality of the product(s) offered (see clause titled Brand

“Name or Equal” set forth in Section 552.210-74 of the GSA Acquisition Regulations.)

1.0 SCOPE

This purchase description is for a Mobile Communications Vehicle (MCV) based upon a light duty pickup truck platform modified with increased gross vehicle weight ratings and with an overall appearance of a sport utility vehicle. The scope of this effort is to produce a “rack ready” vehicle platform for Government provided and installed communications equipment. The exterior of the vehicle shall include an antenna mounting platform.

The interior of the vehicle shall be configured with racks and mounting points for equipment.

Consistency in configuration across the fleet, adherence to design tolerances, and accurate and complete design documentation are extremely important to ensure the Government installed communications package can consistently be integrated into the MCV and to facilitate maintenance of the MCV. The required operational life of the MCV is a minimum of ten (10) years, so the ability to maintain the fleet by government/military personal is important.

The MCV will be employed worldwide, transported on enclosed semi-trailers, C-5, and C-17 aircraft to its mission areas. The MCV’s mission dictates the need for high reliability. The vehicle will be on public display and requires an automotive “Class A” exterior finish. Vehicle, body, equipment, and accessories shall be provided as specified herein.

2.0 APPLICABLE DOCUMENTS

2.1 FEDERAL STANDARDS AND CODES

Code of Federal Regulations 49 CFR 393 (FMCSR) and 571 (FMVSS)

Application for copies of DOT publication should reference the code of Federal Regulations, 49 CFR, and the Federal Register and should be addressed to the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.) They may also be accessed on the Internet through GPO Access at http://www.access.gpo.gov.

MIL-STD- 209K, Interface Standard for Lift and Tie Down Provisions.

MIL-STD-810G, Department of Defense Test Method Standard for Environmental Engineering Considerations and Laboratory Tests.

MIL-STD-1366E, Interface Standard for Transportability Criteria.

MIL-STD-1472G, Department of Defense Design Criteria Standard Human Engineering.

Military Hand Book (MIL-HDBK) 1791, Designing for Internal Aerial Delivery in Fixed Wing Aircraft (for guidance only).

2.2 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70: National Electrical Code®

NFPA 1901: Standard for Automotive Fire Apparatus

Application for copies of the standard should apply to NFPA, 1 Batterymarch Park, PO Box 9101, Quincy, MA 02269-9101, An International

Codes and Standards Organization

2.3 SOCIETY OF AUTOMOTIVE ENGINEERS, INC

J163 - Low Tension Wiring and Cable Terminals and Splice Clips.

J429 - Mechanical and Material Requirements for Externally Threaded Fasteners.

J537 - Storage Batteries.

J541 - Voltage Drop for Starting Motor Circuits.

J551 - Measurement of Electromagnetic Radiation from Motor Vehicles and Devices.

http://www.access.gpo.gov/ http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=70

J553 - Circuit Breakers.

J560 - Primary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable.

J561 - Electric Terminals-Eyelet and Spade Type.

J575 - Tests for Motor Vehicle Lighting Devices & Components.

J576 - Plastic Materials, For Use in Optical Parts Such As Lenses and Reflectors of Motor Vehicle Lighting Devices.

J578 - Color Specification for Electric Signal Lighting Devices.

J595 - Flashing Warning Lamps for Authorized Emergency, Maintenance, and Service Vehicles.

J638 - Test Procedure and Ratings for Hot Water Heaters for Motor Vehicles.

J639 - Safety Practices for Mechanical Vapor Compression Refrigeration Equipment or Systems Used To Cool Passenger Compartment of

Motor Vehicles.

J689 - Approach, Departure, and Ramp Breakover Angles.

J682 – Front and Rear Wheel Splash and Stone Throw Protection.

J683 - Tire Chain Clearance.

J771 - Automotive Printed Circuits.

J858 - Electrical Terminals, Blade Type.

J928 - Electrical Terminals, Pin and Receptacle Type.

1054 - Warning Lamp, Alternating Flashers.

J1127 - Battery Cable.

J1128 - Low Tension Primary Cable.

J1199 - Mechanical and Material Requirements for Metric Externally Threaded Steel Fasteners.

J1292 -Automobile, Truck, Truck-Tractor, Trailer, and Motor Coach Wiring.

J1349 - Engine Power Test Code, Spark Ignition and Diesel.

J1318 - Strobe Warning Lights.

Applications for copies of SAE publications should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale, PA 15096

2.4 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI S1.4-1983 (R2006)/ANSI S1.4A-1985 (R2006) Specification for Sound Level Meters

ANSI standards may be found at:

http://webstore.ansi.org

2.5 OTHER STANDARDS

American Society of Mechanical Engineers/American National Standards Institute (ASME/ANSI) B18.18.1M, Inspection and Quality

Assurance for General Purpose Fasteners.

ASME Y14.5, Dimensioning and Tollerancing

Institute of Electrical and Electronics Engineers (IEEE) 62.41, Guide on Surge Environment in Low-Voltage (1000V and Less) AC Power

Circuits.

Technology and Maintenance Council (TMC) Recommended Practices (RP) 803 - Pre-Service Vehicle Inspection.

Published by The Technical and Maintenance Council of the American Trucking Association, 2200 Mill Road, Alexandria, VA 22314.

Space and Naval Warfare Systems Center (SPAWARSYSCEN) Atlantic, MCV Drawing Package Standard Operating Procedures (SOP)

2.6 ORDER OF PRECEDENCE

In the event of a conflict between the text of this purchase description and the references cited above, the most stringent requirements, as determined by the government, takes precedence. Nothing in this purchase description, however, supersedes applicable state and federal safety laws and regulations and the requirements set forth in the vehicle manufacturer’s Bodybuilders and Incomplete Vehicle Manuals.

http://webstore.ansi.org/

3.0 REQUIREMENTS

Materials shall be as specified herein. When materials are not specified, the vehicle and all parts thereof shall be furnished to provide the intended function, durability, safety, and maintain good long-term appearance. All materials shall be new, shall be suitable for the intended purpose, and shall be free of any characteristics or defects in material and workmanship, which may affect the performance, function, durability, and serviceability of the finished vehicle, or detract from its appearance. Defective component or rebuilt components shall not be used. No wood shall be used in the vehicle. Parts, equipment, and assemblies, which have been repaired or modified to overcome deficiencies, shall not be furnished without the approval of the contracting officer. Component parts and units shall be manufactured to definite standard dimensions with proper fits, clearances, and uniformity. Welded, bolted, and riveted construction utilized shall be in accordance with the highest standards of industry. Dissimilar metals shall be isolated against corrosive action. The government reserves the right to make the final determination of the suitability of all components and their arrangement on and in the vehicle

All conversions and modifications to the Vehicle shall conform to all requirements of the Vehicle manufacturer’s Body Builders Layout Book and

Incomplete Vehicle Manual applicable to the incomplete Vehicle model and year of manufacture. Detailed literature, photos, and other illustrative materials of similar vehicles manufactured shall be submitted with the offer. Submitted material is considered for reference only, shall not constitute any stated or implied exception to the requirements herein, and shall not be used to validate the offer.

Due to the complex scope of the requirements and the substantial modifications to the base vehicle, the Successful Offeror must have means to perform the work in the standing position while under the vehicle. The facilities performing the work shall be equipped with service/work pits or suitably configured vehicle lifts. Government personnel shall only use the pits or lifts to inspect the vehicles. Work and inspection using mechanic creepers or the like shall be avoided. The facilities performing the work shall be brightly illuminated considering the amount of black finishes on the interior/exterior of the vehicle. Failure to support and utilize these provisions increases the risk of defects and rejection of the vehicle by Government.

The Offeror shall ensure that the application and installation of major subcomponents and systems is compliant with subcomponent vendors’ requirements and recommendations.

The Government reserves the right to make the final determination of the suitability of all components and their arrangement on and in the vehicle.

The Successful Offeror shall not proceed with base vehicle modifications until Government approval of plans has been received. The Successful

Offeror shall allow 5 working days for Government review of plans.

3.1 BASE VEHICLE

The base vehicle shall be a 2015 Ford F-350 Crew Cab Pick-Up, or equal. Equivalent models must be from a U.S. headquartered company and shall have equal or greater interior dimensions.

The base vehicle shall be configured with the following Original Equipment Manufacturer (OEM) equipment/features, prior to modification:

Lariat trim level (Lariat Ultimate trim level is not preferred)

Minimum 6.2-liter engine with 385 Horse Power /405 Ft-Lbs of torque

The vehicle shall run on 87 octane gasoline

The vehicle shall run on E85 ethanol fuel

The gas tank shall have a minimum capacity of 35 gallons

50 state emissions

Engine block heater powered by 120 VAC

Stationary elevated idle control

Automatic transmission

Limited slip rear axle

Single Rear Wheels

OEM Heaviest Duty Service Front Suspension Package, 6000 pounds minimum

Anti-lock Brake System- 4 wheel

Automatic Traction Control

Roll Stability Control

Delete Tire Pressure Monitoring System (Ford Fleet Option Code 18L)

Electronic-Shift-On- the-Fly 4-wheel drive

Skid plates for transfer case and fuel tank

Splash guards for all tires

Fog lamps

Long wheel base (172”)

Front seats shall be 40/console/40 configuration

Bucket front seats with four way adjustable headrests

Leather front seats

Heated/cooled front seats

All-weather floor rubber mats for front seats

Dark tinted rear door glass- privacy

Passenger side airbag over-ride switch mechanism

Power, heated, telescoping, power fold-away side mirrors

Power windows and door locks

Reverse obstacle sensor

Cruise control

Tilt and telescoping steering wheel

Front license plate bracket

Dual zone (front/rear) air

Upfitter switches

On-Board Diagnostic (OBD) II port to access vehicle system errors and sensor information

Navigation system

AM/FM stereo, digital clock and CD player with MP3 capability

Rear view camera with 8 inch touchscreen

Black exterior body color

Black interior color and seats

Black interior carpeting

The base vehicle shall be a 2015 Ford F-350 Crew Cab Pick-Up, or equal. Offering: Base Vehicle

Manufacturer: _______________________________________________________

Model: ________________________________________________________

Engine Make/Model/Torque/HP: _________________________________________

Transmission Make/Model/Speed: _________________________________________

Trim Level:____________________________________________________________

3.1.1 BASE VEHICLE MODIFICATIONS AND UPGRADES

The vehicle shall meet all DOT and FMVSS safety standards after modification. Modifications shall not disable vehicle OEM features, unless specified within. Modifications and upgrades shall be performed in accordance to the OEM published Body Builders Layout Book, Design

Recommendations, and Incomplete Vehicle Manual.

3.1.1.1 PAYLOAD CAPACITY AND GVWR UPGRADES

The payload capacity of the MCV shall be a minimum of 2,800 pounds. Payload shall include supplies, Government Furnished Equipment, and the driver and two passengers rated at 220 pounds each. Curb weight shall include the MCV as specified herein including a full fuel tank and all equipment specified within, HVAC, batteries, generators, body, racks, etc. Vehicle as completed, in road travel configuration (full curb weight, including full fuel tank, MCV fluid tanks, all mounted equipment, and 2,800 pounds payload) shall be below the GAWR at each axle and below the

GVWR overall. The completed vehicle payload capacities (available after all modifications stated within) shall be a minimum of 1,800 pounds on the rear axle and 1,000 pounds on the front axle. To achieve the specified payload capacity, the GVWR of the MCV shall exceed 10,000 pounds.

Detailed drawings showing weights and distribution calculations shall be provided at the MCV design reviews. The design to accommodate the payload upgrades shall be approved by the Government at the Verification Design Review.

3.1.1.2 REAR AXLE UPGRADES

The base vehicle rear axle shall be replaced with an aftermarket solution to achieve the specified payload capacity. The rear axle upgrade shall use

OEM components to the maximum extent possible.

Special parts may be required, such as lug offsets, which shall be identified and made readily available.

The MCV rear axle payload capacity shall be a minimum of 1,800 pounds.

A suggested source of supply for the rear axle and the installation is Roush Industries, the POC is:

Edward G. Rathke

Manager - Chassis and Program Engineering

Roush Industries

333 Republic Dr. Allen Park, MI 48101

Work: (313) 425-2320

Fax: (313) 425-2790 edward.rathke@roush.com

The OEM Anti-Lock Braking System shall remain fully functional.

The rear axle configuration shall be approved by the Government at the Verification Design Review.

Offering: Rear Axle

Ratings: ________________________________________________________ tel:%28313%29%20425-2320 tel:%28313%29%20425-2790 mailto:edward.rathke@roush.com

3.1.1.3 SUSPENSION UPGRADES

An air spring suspension system shall be installed on the front and rear axles, meeting the required FAWR and RAWR to adequately support the payload requirements specified within and to provide a smoother ride. The system shall include all plumbing, compressor, tanks, controls, valves, limit switches, four corner air management system, air springs and mounting hardware.

The air spring suspension system shall have selectable preset height adjustments and shall be auto leveling.

The air spring suspension shall have a remote controlled dump valve.

Controls for the air spring suspension system, to include an on/off switch, shall be located on the front dash in reach of the driver.

The vehicle placard with the modified vehicle’s Gross Vehicle Weight Rating (GVWR) shall be installed on the vehicle.

The front axle air suspension shall be a two stage system, completely replacing the OEM spring coils and shock absorbers. The air spring shall be set at the normal OEM (stock) ride height. The front air suspension capacity shall not be less than the rating of the rear axle. The suspension shall be installed in accordance to the manufacturer’s instructions and the OEM Body Builder guidelines. The suspension brackets shall be finished black.

The rear axle air suspension shall be a four link system, completely replacing the OEM leaf springs, sway bar and shocks. The air spring shall be set at the normal OEM (stock) ride height. The rear air suspension capacity shall not be less than the rating of the rear axle. The suspension shall be installed in accordance to the manufacturer’s instructions and the OEM Body Builder guidelines. The suspension brackets shall be finished black.

A suggested source of supply (not mandatory) for the air spring suspension and the installation is:

Mark Steck

Kelderman Air Ride Suspension Systems

2686 Highway 92

Oskalooosa, IA 52577

Phone 641-673-0468

Fax: 641-673-4168 www.kelderman.com http://www.kelderman.com/

The final configuration of the air suspension system shall be approved by the Government at the Verification Design Review.

Offering: Front Axle Air Ride Suspension

Offering: Rear Axle Air Ride Suspension

3.1.1.4 TIRES AND WHEELS UPGRADES

The tires shall be rated to meet the specified payload requirements, GVWR, FAWR, and RAWR.

Single rear wheels must be provided on the rear axle to comply with the ground transport requirements specified within.

The front and rear tires must be interchangeable. Special lug offsets may be required on the front and rear axles.

Tires and wheels shall be rated consistent with the FAWR/RAWR needed to comply with the payload requirement specified within.

Run-flat tires or run-flat inserts shall be installed on the MCV.

The run-flat tire system shall meet or exceed the Finabel standard of 30 miles at 30 mph.

The run-flat tire system shall be installable using standard tire mounting equipment.

Tire brand name must be from a U.S. headquartered company.

The tire and wheel assemblies shall be compatible with Hunter Engineering Company TCX621HD Compact Heavy Duty Tire Changer and FM02

Forecematch HD Wheel Balancer.

One (1) full size spare wheel and tire matching the MCV wheel and tires shall be mounted underneath the MCV.

A set of tire changing equipment that is properly rated for the MCV’s gross MCV weight, shall be securely mounted in or on the MCV.

Neither the spare tire nor the changing equipment shall be visible from the exterior of the MCV when it is mounted in its storage position.

The tire/wheel assembly, run flat solution, and wheel finish shall be approved by the Government at the Verification Design Review.

3.1.1.5 BODY STYLE CONFIGURATION AND EXTERIOR UPGRADES

The rear section of the base vehicle shall be enclosed. The open pickup bed of the base vehicle shall be converted to an enclosed body style. The converted body style shall resemble a full size SUV, such as a Ford Expedition, or similar.

There shall be a section of cabin body added, with no windows and no door hardware (approximately the width of the rear OEM vehicle door) located between the first and second row cabin doors. This extended body section shall utilize new OEM sheet metal body parts/panels that are readily available.

The rear enclosed body section shall be completely metallic. Fiberglass or composite body panels and bed toppers are not acceptable. The enclosed body section may utilize new OEM sheet metal body parts/panels that are readily available and other custom manufactured parts as needed. The fit, finish, and appearance of the enclosed body shall be consistent with the OEM body style. Custom body panels/parts may be required. Custom parts shall be identified and shall be made readily available for purchase to support repairs for the 10-year life of the vehicle.

3.1.1.6 DOORS, GLASS WINDOWS, SOILD PANELS

The MCV shall have six (6) functional side doors.

The second row doors shall only open from the interior of the vehicle. The second row doors will be used for access to the interior of Racks 1 and 2 for installation and maintenance of equipment.

Doors shall have power locks.

Doors shall be lockable using a fob and keys.

A minimum of four (4) key shall be included per MCV.

Child safety locks on doors shall be disabled.

Doors shall have power windows.

Door windows shall be tinted to allow a maximum of 5% visible light transmission.

Rain guards shall be installed on the front and rear side windows.

Opaque (0% visibility), black fabric interior removable window coverings shall be provided for the rear windows.

The rear hatch shall be a full size lift gate unless otherwise approved by the Government

The lift gate shall have power lock.

The lift gate shall be lockable using the same fob and keys as other doors

The lift gate shall remain in the fully open position without user intervention.

When the lift gate is in the open position, rain or rain run-off from the roof or lift gate shall not drip between the lift gate and the roof of the vehicle.

There shall be no glass behind the second row passenger door windows. No glass in the lift gate.

Formed sheet metal panels matching the OEM skin, matching the contour of OEM windows, and matching the specified paint finish and trim shall be installed in place of any glass windows other than on the four (4) doors and windshield.

The body configuration and style shall be approved by the Government at the Verification Design Review.

3.1.1.7 BODY ACCESSORIES

The rear exterior signal lights shall have reinforced covers for protection.

Running boards, (similar in style and configuration to Ford Option Code 18B) in color black, shall be provided. The running boards shall extend from the front of the first row doors to the back of the second row doors. Running boards shall have a flat non-skid surface along the entire length.

The running board width shall be a minimum of 6 inches.

If the mirrors are power-folding, failure of the power folding shall not render the mirrors incapable of folding manually towards or away from the body of the vehicle.

3.1.1.8 THERMAL AND ACOUSTICAL PROTECTION

The purpose of the following requirements is to minimize exhaust and ambient heat transfer and sound attenuation in the cabin or under-hood.

A ceramic coating, JetHot Extreme2500 series, or equal with black finish shall be applied to the entire exhaust system from the catalytic converter back for improved heat dissipation. This coating cannot be applied to the parts in the field.

The exhaust system ceramic coating shall be Jet Hot, model Extreme 2500, or equal.

Offering: Ceramic Coating

A water-based spray on sound dampening coating, Mascoat LizardSkin Sound Control, or equal shall be applied to the interior rear cabin floor, interior roof, interior side walls, side doors, and the interior of the rear lift-gate. The coating shall also be applied to all exterior underbody sections and the fuel tank. The coating shall have a Class A fire rating and the color shall be black. The coating shall be installed in accordance to manufacturer’s instructions, including the use of special application tools. Proper masking techniques shall be utilized. A minimum of two (2) 20 mil coats shall be applied, resulting in a minimum thickness of 1 mm.

The sound dampening coating shall be Mascoat, model LizardSkin Sound Control, or equal.

Offering: Sound Dampening Coating

A water-based spray on ceramic insulation, Mascoat LizardSkin Ceramic Insulation, or equal shall be applied to the interior rear cabin floor, interior roof, interior side walls, side doors, and the interior of the rear lift-gate. The insulation shall also be applied to all exterior underbody sections and the fuel tank. The insulation shall be applied after the sound dampening coating. The insulation shall have a Class A fire rating and the color shall be black. The insulation shall be installed in accordance to manufacturer’s instructions, including the use of special application tools. Proper masking techniques shall be utilized. A minimum of two (2) 20 mil coats shall be applied, resulting in a minimum thickness of 1 mm.

The insulation shall be Mascoat, model LizardSkin Ceramic Insulation, or equal.

Offering: Insulation

Mechanical (forced) ventilation shall be provided and installed to assist in dissipating heat from the engine compartment, supplementary to the

OEM cooling system.

3.1.1.9 MCV FINISH AND APPEARANCE

The MCV shall be painted with uniformly colored automotive black paint, OEM color code G900, with no metallic content. The final finish shall be a base coat and clear coat. All exterior surfaces shall be finished to automotive “Class A” standards, unless noted otherwise. The intent and purpose of this non-metallic finish is to enable the user to maintain a consistent appearance throughout the life of the MCV and the ability to remove/replace parts from one MCV to another on as needed basis. To obtain a consistent color matching finish for the MCV, painting of the MCV and all components specified in one process is highly recommended.

Aftermarket exterior trim added shall match the OEM's trim level, fit, and finish.

The MCV’s fuel fill line shall be installed in accordance to OEM guidelines, properly concealed, and shall support a flow rate that is not less than the base vehicle.

3.1.1.10 MCV DIMENSIONS

The overall height, with tires inflated to the manufacturer's recommended pressure and measured to the highest point of the MCV, shall be a maximum of 82 inches. The air springs may be deflated to meet this requirement.

The overall length shall be a maximum of 275 inches, excluding tie downs as specified within.

The overall width, not including mirrors, shall be a maximum of 80 inches.

3.1.1.11 BACK UP CAMERA

The MCV shall have a backup color camera integrated into the OEM dash display. The rear camera shall be flush mounted and automatically activate when the MCV is in reverse gear.

A Freedom In Motion MyTouch LOCKPICK 2 interface, or equivalent, with a minimum of three (3) camera inputs shall be installed using system specific plug and play cables. The LOCKPICK shall be compatible with the in-dash touch screen and associated computer. The backup camera shall be connected to the navigation screen through the LOCKPICK. The backup camera’s video feed shall automatically display on the navigation screen with the vehicle is in reverse and when it is manually selected.

Offering: LOCKPICK

3.1.1.12 PROHIBITED/DISABLED VEHICLE FEATURES

The OEM vehicle tracking systems shall NOT be installed.

Tire Pressure Monitoring System (TPMS) shall not be provided.

The OEM keyless entry shall be disabled.

The OEM supplemental restraints, excluding the driver's and passenger’s seats, shall be disabled or shall be removed.

The OEM back up alarm shall be disabled.

The OEM ignition key shall be the only means to start the vehicle (no remote start). Disabling remote start through the user options menu does not satisfy this requirement.

Any GPS device/feature shall only provide position location information to users within the MCV.

Any Bluetooth capability shall disabled (not just turned off through the user options menu) or not installed.

3.2 AUXILLIARY HEATING VENTILATION AND AIR CONDITIONING (HVAC)

An auxiliary Heating Ventilation and Air Conditioning (HVAC) system capable of providing a minimum of 32,000 BTU of cooling and 30,000 BTU of heating shall be installed in the MCV.

The auxiliary HVAC shall be located inside the MCV.

Supply and return air for the auxiliary HVAC shall be ducted to provide adequate cooling to each equipment rack and equipment installation location in the rear of the MCV.

In the rear of the MCV, auxiliary HVAC air vents shall allow for airflow in the direction of the rear captain’s chair.

Controls for the auxiliary HVAC unit shall be accessible by a person in the rear captain’s chair wearing a seat belt.

Controls shall provide for thermostatic temperature control and manual fan speed control of the auxiliary HVAC.

Condensing unit shall be located under-hood.

Drip pan and overflow tube shall be provided under the evaporator coil.

The auxiliary HVAC shall be capable of operating from onboard vehicle power.

The auxiliary HVAC shall operate from 120 VAC shore power, with chassis engine off.

The auxiliary HVAC shore power connection shall be located on the exterior curbside of the vehicle.

3.3 AC ELETRICAL GENERATOR SYSTEM

The MCV shall have an under-hood Alternating Current (AC) electrical generator system installed IAW manufacturer's instructions.

The generator shall have a continuous power rating of a minimum of 8,000 W at the OEM chassis engine's high idle speed, frequency stability within

+/- 0.2Hz, and voltage and total harmonic distortion 2.5% maximum.

The under-hood AC electrical generator system shall be an Aura Systems, AuraGen G8500X ICS (Heavy Duty) with enhanced electromagnetic interference (EMI) filtering and shielded cables, or equal, and shall include the following components:

8.5 kW AuraGen Mobile Power Generator (Heavy Duty)

8.5 kW AuraGen Power Control Unit (PCU), Inverter Charging System (ICS) capable of inverting a minimum of 3.5 kW from the payload batteries, with EMI filtering, 24 VDC Input (Heavy Duty)

Signal Cable Set, ICS, Braided, Shielded (Heavy Duty)

Power Cable, Gen-ECU, Shielded, (Heavy Duty)

AC Cable, Pig Tail Out, Shielded, Right angle connector, 3 ft (2 ft shielded, 1 ft bare wires (Heavy Duty)

ICS Cabling Kit

Control Panel, ICS System (Heavy Duty)

EMI shielded enclosure

Idle controller compatible with base MCV

ICS computer interface cable

The AC electrical generator system shall be programmed with the appropriate charging profile for the payload batteries.

The Power Control Unit (PCU) shall be mounted in the rear of the MCV behind the driver and assistant driver. The PCU shall undergo a full load test

(8,000 W minimum) and inspection by the manufacturer prior to delivery and installation into the MCV.

An EMI shielded cover shall be installed over all exposed terminals of the PCU.

The AC electrical generator system and mounting locations for all components shall be approved by the Government at a Verification Design

Review.

Offering: AC Electrical Generator System

Ratings:_________________________________________________________

Features:__________________________________________________________

3.4 PAYLOAD BATTERY SYSTEM

A 24 VDC payload battery system shall be provided and shall be connected to the AC electrical generator system.

The payload batteries shall be rated for operations from -32 o C to 55 o C.

The payload battery bank shall have a total minimum capacity at a 10-hour rate of 684 AH.

The payload battery bank shall be rated for a minimum of 400 discharge/recharge cycles to 80% capacity.

The payload batteries shall be dry cell.

The payload batteries shall be mounted in the rear of the MCV enclosed in boxes that vent to the exterior of the MCV at a location to be approved by the Government at a Verification Design Review. The Offeror may propose other battery mounting locations, such as under the vehicle, for approval by the Government.

The exterior of the battery boxes shall be covered in carpet.

The battery boxes shall be constructed of non-metallic materials or sufficiently insulated to prevent arching and accidental shock.

The batteries installed in the boxes shall contain adequate tie downs or methods of securing the batteries constructed of non-metallic or sufficiently insulated materials to prevent dislocation of batteries while in transit.

Covers shall be installed on all exposed battery terminals.

Each battery box shall support a minimum of 250 pounds equally distributed across the lid.

The battery boxes shall have tie down rails along each side of the top of the boxes for customer use.

The payload battery bank shall be electrically bonded to the vehicle chassis.

The battery boxes shall be electrically bonded to the vehicle chassis.

The battery system and mounting locations for all components shall be approved by the Government at a Verification Design Review.

3.4.1 ACCESSORY POWER-PAYLOAD BATTERY

Power for aftermarket lighting shall be drawn from the entire payload battery bank to keep the charge of the batteries balanced.

A power panel with breakers for aftermarket lighting shall be installed road side of Rack 3.

The power panel shall include a digital voltmeter that displays the payload battery bank’s voltage with a minimum resolution of 0.1 VDC.

The digital voltmeter shall have a programmable alarm that sounds at specified high and low voltage levels.

3.4.2 AFTERMARKET LIGHTING-PAYLOAD BATTERY

The power for aftermarket interior lighting shall be sourced across the entire payload battery bank (not a single battery).

Selectable red and white sealed ambient LED lights with separate on/off switches and dimming capability shall be installed on the bottom of the cable trays forward of racks 3 and 4 and along the bottom edge of the printer bench, Rack 1, and Rack 2.

LED lights shall be installed on the interior of the MCV near the lift gate and will illuminate when the door is opened.

Three (3) LED task lights shall be installed on the ceiling of the operator area and two (2) LED task light shall be installed on the ceiling of the rear compartment: one light shall be located curbside of rear captain’s chair, one light shall be located roadside of the rear captain’s chair, one light shall be located forward of the captain’s chair, near Rack 1, one light shall be located on the curbside of Rack 5, and one light shall be located on the street side of Rack 5.

The direction of the task lights shall be user adjustable.

The task lights shall have user selectable red and white light. The task lights’ intensity shall be adjustable.

The type and location of the lights shall be approved by the Government at the Verification Design Review.

3.5 DC ELECTRICAL SYSTEMS

3.5.1 VEHICLE BATTERY

The vehicle battery shall not be a flooded wet cell.

The vehicle battery shall be rated to operate at temperatures present under the hood while the vehicle is running in an ambient temperatures from -32 o C to 55 o C.

An alternate means to start the vehicle from the payload batteries within 15 seconds, separate from the vehicle battery, shall be provided using a momentary switch located on the dash.

The jump-start switch shall be protected from inadvertent contact.

3.5.2 ACCESSORY POWER-VEHICLE BATERY

The 12 VDC vehicle battery systems shall consist of two (2) branches as follows: one (1) branch shall power the OEM chassis components, equipment, accessories, and FMVSS lighting; the other branch shall power the emergency lights/siren, the alarm system, and the idle controller.

A power panel with individually fused circuits for aftermarket components powered from the vehicle battery shall be installed.

The Successful Offer shall provide the nominal power draw from the vehicle battery as a result of aftermarket additions in both active and standby modes.

3.6 DC ELECTRICAL WIRING

All DC wiring shall be in accordance with the applicable portion of SAE J1292.

All DC wiring mounted to the chassis or outside the body shall be stranded copper conductors.

All DC wiring shall be routed in flexible loom or conduit (tie wraps are not acceptable) and in accordance to the OEM’s body builder guidelines.

All wiring shall be secured to prevent snags and pinching that could damage or disconnect the wire.

The wiring terminals used in all DC wiring shall grip the wire insulation as well as the conductor.

Fasteners, conduit, and conduit fittings for electrical wiring shall not exhibit electrolysis with adjacent materials.

All exterior lighting shall be wired within the body to the exterior lights.

Exterior wiring shall be accessible for replacement without removing any component of the MCV.

Grommets or electrical bulkhead fittings shall be employed for any wire passing through a structural member.

All DC wire shall be color-coded as specified in SAE J560.

The wire and circuit breaker size shall be as follows:

Wire size (minimum) Circuit breaker (maximum)

18 AWG 5 amperes

16 AWG 10 amperes

14 AWG 15 amperes

12 AWG 20 amperes

10 AWG 30 amperes

8 AWG 50 amperes

All electrical systems added to the OEM vehicle shall be grounded to the vehicle chassis with a maximum resistance of 0.2 Ohms measured between the equipment and the chassis.

Antiseise shall be used between ground lugs and the vehicle chassis.

All points on the vehicle chassis used for grounding shall be electrically connected with a maximum of 0.2 Ohms between grounding points.

3.7 SECURITY ALARM SYSTEM

A two-way security system, Viper model 3303 or equal, capable of signaling a remote control device if tampering of the vehicle occurs, shall be provided.

The aftermarket security system shall interoperate with the OEM alarm system.

The security system shall NOT have the ability to be controlled by a cellular device.

The security system shall be operated with a dedicated remote control device.

The security system remote shall have a minimum Line of Sight (LoS) range of 100 feet.

A minimum of four (4) alarm LCD 2-way remotes shall be included per MCV.

The security system shall allow the user to arm and disarm the alarm.

The security system shall NOT provide the ability to unlock any doors.

The security system shall not allow starting of the MCV if the alarm has been activated.

The opening of hatch, door, hood, or lift gate to the interior of the MCV shall activate the alarm when it is armed.

The alarm shall have the following features:

Panic mode.

Minimum 110 decibel siren.

Visual and audible effects upon activation of alarm.

Visual deterrent Light Emitting Diode (LED).

Anti-nuisance circuitry.

Valet switch/emergency disarm.

A module interface, such as the DBALL module, shall be installed with the alarm system.

The alarm system and mounting locations for all components shall be approved by the Government at a Verification Design Review.

Offering: Alarm System

3.8 EMERGENCY LIGHTING AND PUBLIC ADDRESS/SIREN

The MCV shall be equipped with a complete Whelen Model HHS2200, all LED emergency lights, sires, and PA system or equal.

The emergency system shall be installed that includes sirens, speakers; headlamp flashers, taillight flashers, and front grill lights.

The light package shall include the following components:

Whelen console siren/light controller: Model HHS2200, or equivalent

Siren: Whelen SA314 Series (SA314B), or equivalent, speaker with black epoxy coated finish.

Front Grill Lights: Whelen TIR3™ Series Super-LED® Lightheads (RS*03ZCR), or equivalent; 5 Scan-Lock with Flash Pattern and Steady

Burn with Synchronize Feature, for Horizontal Mounting, Blue and Red.

Two (2) front and two (2) rear Whelen #S690CCCC Hideaway Strobes, or equal

The emergency lights, sirens, and PA system shall include the following:

Grill mounted red and blue law enforcement style lights and sirens shall be installed on the MCV.

The MCV's corner lights shall have strobe lights.

The strobe light activation switch(s) shall be accessible by personnel seated in both front seats.

The speaker shall be mounted behind the grill.

The siren shall be configured for hail and yelp only.

A microphone shall be included for PA capability.

The emergency lighting and PA system and mounting locations for all components shall be approved by the Government at a Verification Design

Review.

Offering: Warning System

3.9 EXTERIOR UPFITTING

The exterior assemblies shall include exact finish and appearance as specified for the MCV.

3.9.1 ANTENNA PLATFORM

An antenna mounting platform a minimum of 139 inches x 50 inches in size shall be installed on the roof of the MCV as depicted in Figure 5.

The platform shall be constructed and installed to approved drawings with tolerances of +/- .01

The antenna mounting platform shall not exceed the footprint of the MCV’s roof.

The antenna platform shall be a minimum of 1 inch and a maximum of 2 inches above the MCV roof at the point closest to the roof.

The antenna platform shall be removable by a maximum of two (2) personnel.

The antenna mounting platform shall be electrically bonded to the MCV frame.

The top of the antenna platform shall not be made from a ferrous metal.

Fasteners on the antenna platform shall be austenitic stainless steel.

A wind deflector shall be installed on the front of the antenna platform.

The antenna platform shall have water drainage to prevent pooling that does not discharge above the side windows.

The antenna platform shall support the weight distribution as depicted in Figure 6.

Details of the antenna platform design, to include a strength and integrity analysis performed by a certified Professional Engineer registered in the

United States, shall be approved by the Government at the Verification Design Review.

3.9.2 GD M20-20 MONTING PLATE FOR IN MOTION VSAT

A General Dynamics (GD) M20-20 mounting plate shall be provided and installed on the roof of the MCV (not on the antenna platform).

The roof shall be reinforced to support the weight of a minimum of 175 pounds under the GD M20-20 mounting plate without sagging.

The support shall have a local rotational stiffness about the vertical axis of a minimum of 5000 foot-pounds (6800 Newton-meters) per degree.

"Local" stiffness is defined as stiffness from the mount to the frame.

The area of the roof or antenna platform on the driver’s side of the GD M20-20 mounting plate shall be reinforced to support a minimum of 250 pounds allowing a person to stand next to the antenna to perform maintenance without structural deflection.

The Offeror shall consult with the GD SATCOM Technologies SOTM engineers regarding mount installation.

The mounting plate shall be constructed and installed to approve drawings with tolerances of +/- .01.

The overall installation design and structural integration of the GD M20-20 mounting plate into the MCV, including a finite element structural analysis, shall be performed by a Professional Engineer registered in the United States. The complete design installation solution, location, and engineering analysis shall be provide prior to and reviewed and approved by the Government at the verification design review.

3.9.3 ANTENNA SIGNAL ENTRY PANEL

Two (2) removable metal plates that can be modified by the Government for use as antenna cable Signal Entry Panels (SEPs) shall be provided on the roof of the MCV.

The antenna SEP plates shall be made of stainless steel of a quarter inch (0.25") thickness. Each antenna SEP plate shall have a usable surface area of approximately twelve inches by fifteen inches (12" x 15").

The antenna SEPs shall be accessible from both the roof and the passenger compartment without moving any vehicle roof material, wiring etc.

The addition of the antenna SEPs shall not affect the water tightness of the MCV and shall not require preventive maintenance.

The exact locations and dimensions of the antenna SEPs shall be approved by the Government at a Verification Design Review.

3.9.4 CURBSIDE SIGNAL ENTRY PANEL

One (1) external SEP shall be installed on the curbside rear quarter panel. The Government will install the signal entry points in the vendor installed curbside SEP after delivery of the MCV.

The door for the curbside SEP shall be flush mounted with the exterior of the MCV and match the trim of the MCV.

The curbside SEP door shall open upward.

The door shall be secured with a combination lock that shall be opened using a minimum of four (4) digits.

The ability to secure the SEP door in the open position shall be provided.

Four (4) footman’s loops shall be installed on the bottom of the SEP for use as a tie point for cables for strain relief.

One (1) footman’s loop shall be installed inside the wheel well of the wheel under the SEP for use as a tie point for cables to secure cables away from the vehicle’s exhaust.

User-controllable sealed LED ambient red and white lighting shall be installed in the curbside SEP for visibility of connectors and labels during low-light operations.

The rear panel of the curbside SEP shall be removable.

The minimum usable dimensions of the rear SEP panel shall be 20 inches wide by 9.5 inches tall.

The rear panel shall be recessed into the vehicle a minimum of 6 inches to provide clearance between the door and panel for connectors.

The SEP shall be constructed and installed to approved drawings with tolerances of +/- .01.

The addition of the external SEP shall not affect the water tightness of the MCV, with the door open or closed, and shall not require preventive maintenance.

The dimensions and exact location of the curbside SEP shall be approved by the Government at a Verification Design Review.

3.10 INTERIOR UPFITTING

The interior layout shall be similar to the conceptual reference provided Figure 1. The exact layout shall be reviewed and approved by the

Government at Verification Design Review.

3.10.1 ELECTROMAGNETIC INTERFERENCE (EMI) SHIELDING

Signals Defenses model SD2500 film shall be applied to all rear windows to employ radio frequency (RF) and infrared (IR) attenuation countermeasures.

Copper Mesh (consisting of 1 layer 8 mesh 0.028”) shall be affixed to entire interior of the MCV’s body. The purpose of the copper mesh is the reduce EMI radiating out of the MCV from internal systems.

A spray-on nickel-based EMI coating (3 mil thick, <=0.7 ohms/square) shall be added onto the interior of the MCV body structures to provide electrical shielding.

3.10.1.1 COPPER MESH INSTALLATION

The following Workmanship Standard shall be employed for application of Electromagnetic Interference (EMI)/TEMPEST/Lightning (ETL) shielding layer on the interior body of the MCV:

Overlap of copper mesh shall be a 1” seam, non-acid fluxed, heated by torch or high-wattage iron, and soldered with electrical solder.

Edges of copper mesh that meet with conductive metal MCV components shall protruding/overlap 1 inch.

The edges of the copper mesh shall be soldered such that unraveling will not occur.

Shield Braid/Ground Strap, ½” minimum width, may be used to join adjacent sections of copper mesh, such as where flexure is encountered between door hinges to frame.

Nonmagnetic stainless fender washers may be used to attach copper mesh to MCV metal components where shield braid will not work.

The metal components must have a continuous bonded path to the MCV frame ground.

The spray ETL coating does not require bare metal to combine with the metal as a continuous shield; a spray overlap provides the link through paint or primer.

Metal windows shall be electrically bonded to the copper ETL layer using the shield braid/ground strap at 6 inch maximum intervals.

The Government shall have the opportunity to inspect the installation of the copper mesh prior to the mesh being covered. The Government shall be notified of the inspection window a minimum of 7 working days in advance.

3.10.2 PRIVACY PARTITION

A rigid opaque privacy partition shall be installed behind driver and assistant driver seats. See Figure 1, MCV Interior Layout for general location of partition.

The partition shall be as light as possible while being strong enough to mount equipment weighing a maximum of 5 lbs, and TVM Ultra NT SCIF

Barrier sheet, Part No. 1800-48-125 shall be affixed to the partition to provide RF and IR countermeasures.

The location of the partition shall be as far forward as possible, with the driver seat in the rearward-most position and in a moderate recline (i.e.

~30°).

A thirteen inch by thirteen inch (13” x 13”) door centered on centerline of the MCV, six inches (6") below the ceiling shall be installed in the partition.

The 13” x 13”’ partition door shall slide sideways and be capable of opening from either side of the partition.

A means to secure the 13”’ x 13”’ partition door in the open and closed positions from either side of the partition shall be provided.

A cable pass through shall be cut in the partition as approved by the Government at a Verification Design Review.

The vehicle’s rear air vents shall be relocated to the privacy partition to blow into the rear compartment.

The partition shall have access panels behind Racks 1 and 2 so equipment within the racks can be accessed for maintenance from the front compartment.

The design and structural integrity of the partition hall be approved by the Government at a Verification Design Review.

3.10.3 BULK HEAD MOUNTING PLATES

Two ¼-inch solid bulkhead mounting plates that can support a minimum of 50 pounds each shall be mounted to the MCV near the rear antenna SEP.

One shall be mounted near the roof and one shall be mounted near the wheel well.

Two grounding straps shall be installed near the curbside rear wheel well that attached to the MCV frame to provide an electrical bond with a maximum of 0.2 Ohms resistance.

A structural member shall be installed below the forward antenna SEP at the outer driver’s side edge of Rack 1, that includes a hinge to support a copper grounding panel, to be installed by the Government, of approximately 5.5 inches wide by 20 inches high.

The structural member shall support a minimum weight of 50 pounds.

Two grounding straps shall be provided near the structural member: one of the grounding straps shall be attached to the antenna platform for connection to the grounding panel through the forward SEP, and the other shall be attached to the MCV frame for connection to the bottom of the grounding panel.

The grounding straps shall be long enough to allow free movement of the panel on the hinge.

The bulkhead plate shall be fabricated and installed to approved drawings with tolerances of +/- .01.

The design and structural integrity of the bulkhead mounting plate systems shall be approved by the Government at a Verification Design Review.

3.10.4 EQUIPMENT RACKS

Five (5) custom fabricated equipment racks shall be installed in the rear of the MCV as depicted in Figure 1.

Racks shall be properly secured to prevent dislocation in the event of a crash.

Racks 3, 4 and 5 shall be removable by a maximum of two (2) personnel.

Racks 3, 4, and 5 shall be a minimum of 20 standard rack units tall and accommodate equipment designed for standard racks 19 inches wide and 19 inches deep.

Racks 3, 4, and 5 shall have uniformly spaced threaded equipment mounting holes every 0.625 inch.

The distance between the rear of racks 3 and 4 and rack 5 shall be a minimum of 6 inches to allow cable routing.

The distance between racks 3 and 4 shall be a minimum of 4.30 inches.

The area around the front (the side facing the operator’s compartment) of racks 3 and 4 shall be framed, with the frame…