MCV_Final_PD.pdf

Purchase Description

Mobile Communications Vehicle (MCV)

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 personnel 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 Federal Motor Carrier Safety Regulations (FMCSR) and 571

Federal Motor Vehicle Safety Standards (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).

MIL-PRF-2471B Performance Specification Coatings, Powder, Thermosetting http://www.access.gpo.gov/

Federal Standard 595- Colors Used in Government Procurement http://www.gsa.gov/portal/content/142623

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.

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.

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

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, Geometric Dimensioning and Tolerancing Guidelines

ASME Y14.100-2004, Engineering Drawing Practices

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.

American Society for Testing and Materials (ASTM) http://www.astm.org/

D-2794 Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid

Deformation (Impact)

C-177 Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission

Properties

The Tire and Rim Association, Inc. -Year Book of TRA standards.

2.6 OTHER DOCUMENTS

Space and Naval Warfare Systems Center (SPAWARSYSCEN) Atlantic, Mobile Communication Vehicle

Drawing Package Standard Operating Procedure (SOP) Version 1.0 http://webstore.ansi.org/ http://www.astm.org/

2.7 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 - OEM Body Builders Layout Book and Guidelines.

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 OEM Body Builders Layout Book applicable to the model and year of manufacture. Due to the complex scope of the requirements and the substantial modifications to the base vehicle, the Successful Offeror shall 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 will only use the pits or lifts to inspect the vehicles. Work and inspection using mechanic creepers or the like should 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 no later than the conclusion of the CDR event. The Successful Offeror shall not proceed with base vehicle modifications until Government approval of plans has been received; refer to verification requirements in section 3.22. The Successful Offeror shall allow five (5) working days for

Government review of design/integration plans unless otherwise specified.

3.1 BASE VEHICLE

The base vehicle shall be a Model Year 2015, one- ton Crew Cab Pick-Up, Crew Chassis-Cab, or equal.

Models shall 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:

Engine with a minimum of 360 Horse Power

The vehicle shall run on 87 octane gasoline

The gas tank shall have a minimum capacity of 35 gallons

EPA 50 state emissions

Engine block heater powered by 120 VAC

Stationary elevated idle control

Automatic transmission-5 speed minimum

Limited slip rear axle

OEM Heaviest Duty Service Front Suspension Package, 6000 pounds minimum

Anti-lock Brake System- 4 wheel

Automatic Traction Control

Delete Tire Pressure Monitoring System as required

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

Skid plates for transfer case and fuel tank

Splash guards for all tires

Fog lamps

Wheel base 172 to 177 inches

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

Driver and passenger frontal airbags

Passenger frontal 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, leather wrapped, steering wheel

Front license plate bracket

Dual zone electronic automatic control (front/rear) air conditioning

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

Front and rear map pockets

Soft armrest grab handle

Power adjustable pedals

Sun visors, driver and passenger with covered mirror

Under-hood service light

Front bumper chrome finish

Front grille chrome finish

Black exterior body color

Black interior color and seats

Black interior carpeting

Refer to section 3.1.1.12 for list of prohibited/disabled vehicle features

The base vehicle shall be a Model Year 2015, Ford F-350 Crew Cab Pick-Up Lariat, Ford Crew Chassis-

Cab Lariat, or equal.

Offering: Base Vehicle

Manufacturer: _______________________________________________________

Model: ________________________________________________________

Engine Make/Model/Torque/HP: _________________________________________

Transmission Make/Model/Speed: _________________________________________

Trim Level:____________________________________________________________

OEM Optional Features: _________________________________________________

3.1.1 BASE VEHICLE MODIFICATIONS AND UPGRADES

The vehicle shall meet all applicable DOT and FMVSS safety standards after modification. Modifications shall not disable vehicle OEM features, unless specified within. The intermediate and final stage manufacturers

(modifiers) shall certify the vehicle ratings and compliance to the Vehicle Safety Act.

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

Note: To achieve the specified payload capacity of the MCV, the GVWR will 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 may require replacement with an aftermarket solution to achieve the specified payload capacity. The rear axle upgrade shall use OEM components to the maximum extent possible. The rear axle shall have a minimum of eight (8) lugs. The rear axle shall be configured with single wheels.

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

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

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

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

Offering: Rear Axle

Manufacturer: _______________________________________________________

Model: ________________________________________________________

Ratings: ________________________________________________________

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. 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 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 front axle. The suspension shall be installed in accordance to the manufacturer’s instructions and the OEM Body Builder Layout Book. 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 brackets shall be finished black. The installation shall be in accordance to the OEM Body Builder Layout Book, specific details are referenced in the section Design Recommendations for suspension systems. A suggested source of supply for the air spring suspension and the installation is:

Kelderman Air Ride Suspension Systems

2686 Highway 92

Oskalooosa, IA 52577

Phone 641-673-0468

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

Offering: Rear Axle Air Ride Suspension

3.1.1.4 TIRES AND WHEELS UPGRADES

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

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

The front, rear, and spare wheels/tires shall be interchangeable. Special lug offsets may be required on the front and rear axles.

The wheel/tire/run-flat assemblies shall be computer balanced after assembly.

Wheels shall be a minimum size of 19.5 inches x 7.5 inches

Wheels shall have a minimum eight (8) lug pattern

Wheels shall be a two-piece take a part design with 18 studs and 36 evenly spaced holes.

Wheels shall include bead-lock.

Studs shall be mounted on the inside of the outer lip of the rim.

Wheels may be steel or aluminum, forged, cast, welded, or machined.

Offset, hub pilot diameter, mounting hole pattern, and mounting hole dimensions shall be compatible with axles and any special lug offsets.

Wheels shall be powder coated per manufacturer’s commercial process, color shall be black, and finish shall be satin.

Center hub covers, matching color and finish of wheels, shall be installed.

Wheels shall be designed and manufactured in accordance to the standards/guidelines published in the Tire and

Rim Association, Inc. Yearbook.

Tires shall have a minimum size of 245/70R 19.5, Load Range H, Speed Rating of M.

Tires shall have a minimum tread depth of 20/32.

The tire tread shall be rated for mud and snow.

Tires shall be suitable for drive axles.

Tires shall be of the same manufacturer/model.

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

Run-flat inserts shall be provided and installed.

Run- flat inserts shall be rated for the size of wheel/tire and the GVW/FAWR/RAWR.

Run-flat inserts shall be compatible with wheels and tires.

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

Typical tire service (hand) tools shall only be required for the installation of run-flat inserts or the tires onto the wheels.

One (1) matching spare wheel/tire with run-flat insert shall be mounted underneath the MCV.

A set of tire changing equipment that is properly rated for the MCV’s GVWR, 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 wheel/tire assembly, run flat insert, 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 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 exterior 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. The modifications shall be in accordance to the OEM Body Builder Layout

Book, specific details are referenced in the section Design Recommendations for fuel fill systems.

3.1.1.6 DOORS, GLASS WINDOWS, SOLID PANELS

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

The second row doors shall only open from the interior of the MCV.

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 keys and interior buttons only (no wireless locking capability).

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

Child safety locks on doors shall be disabled.

The first and third row 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 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 in the second row passenger doors.

There shall be no glass in the rear lift gate.

Formed sheet metal panels matching the OEM skin, matching the contour of OEM windows/lift gate, and matching the specified paint finish and trim shall be installed in place of any glass 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.

An OEM style chrome finish, full width, rear bumper shall be provided.

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 maximize sound attenuation into the cabin.

A ceramic-metallic coating with black finish shall be applied to the exhaust system for improved heat dissipation. The coating shall be applied to the all exterior exhaust surfaces and to the interior of the exhaust components where practicable. The coating shall not be applied to the inner surfaces of the catalytic converter(s), muffler, resonator, or any pipes that include internal baffling. The coating is not required on couplings, clamps, or fasteners. The coating shall be applied on the engine exhaust manifold through the tailpipe.

The ceramic-metallic coating shall be free of volatile organic compounds and shall have a continuous service temperature rating of 2500 o

F. The coating shall have a minimum impact resistance of 70 inch-pounds (ASTM

D2794). The coating shall have a thermal conductivity rating between 0.2 to 1.8 W/mK (ASTM C177). The coating shall be applied to a minimum thickness of 1.5 to 4.0 mils (0.0015 to 0.004 inch)

This coating cannot be applied to the exhaust system in the field. The entire exhaust system shall be removed, disassembled, and shipped to the coating manufacturer/service provider who will provide and apply the coating.

The exhaust components shall be cleaned and prepared before application of the coating. The coating application process requires curing at controlled elevated temperatures in accordance to manufacturer’s instructions. The entire exhaust system, with coating applied, shall then be reassembled and reinstalled onto the

MCV.

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

Offering: Ceramic Coating

A water-based acrylic spray on sound dampening coating 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 volume solids content shall be 50-

55%. The volatile organic content shall not exceed 0.27 pounds/gallon. The wet weight of the coating shall be a maximum of 14 pounds per gallon. The coating’s dried weight shall be a maximum of 0.25 pounds per square foot at 20 mils thickness.

The coating shall be installed in accordance to manufacturer’s instructions, including the use of special application tools. Proper masking techniques shall be utilized to prevent overspray. A minimum of two (2) 20 mil coats shall be applied, resulting in a minimum thickness of 0.040 inch.

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

Offering: Sound Dampening Coating

A water-based acrylic- ceramic spray on insulation 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. The insulation color shall be black. The volume solids content shall be 70.6%. The volatile organic content shall not exceed 0.07 pounds/gallon. The wet weight of the coating shall be a maximum of 5.75 pounds per gallon. The coating’s dried weight shall be a maximum of 0.06 pounds per square foot at 20 mils thickness.

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 0.040 inch.

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

Offering: Insulation

Mechanical (forced) ventilation shall be provided and installed, without reducing ground clearance to assist in dissipating heat from the engine compartment, supplementary to the OEM cooling system. Hood and/or fender vents may be installed The installation shall be in accordance to the OEM Body Builder Layout Book, specific details are referenced in the section Design Recommendations for cooling systems.

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 display interface with a minimum of three (3) camera inputs shall be installed using system specific plug and play cables. The display interface shall be compatible with the in-dash touch screen and associated computer.

The backup camera shall be connected to the navigation screen through the display interface. 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. The input on the display interface shall be user selectable, even when the vehicle is in reverse.

The backup camera display interface shall be a Freedom In Motion, model My Touch Lockpick2, or equal.

Offering: Display Interface

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, (side curtain airbags), excluding the driver's and passenger’s frontal restraints, 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 and not transmit location information.

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

3.2 AUXILIARY 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 HVAC system shall reduce the vehicle’s interior ambient temperature from 49 o C to a maximum of 32 o C in a maximum of 30 minutes measured mid vehicle height above the operator seat. Refer to validation testing requirements in section 4.1.

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.

Independent controls shall provide for user adjustable thermostatic temperature control and manual fan speed control of the auxiliary HVAC. Special components are required to be added to the OEM refrigeration system to enable independent control of the OEM and auxiliary HVAC systems.

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 space available for packaging and installation of the auxiliary HVAC system is limited by the overall layout of the MCV. Refer to Figures 1-5 for interior/exterior equipment space claims. The condensing unit(s) shall be installed under hood or installed under chassis body. If condensing unit(s) are installed under body, they shall be adequately protected from road damage, shall not reduce vehicle ground clearance, shall not be noticeable, and shall provide sufficient airflow and ventilation of discharge heat away from the MCV as to not further elevate under chassis temperature while the vehicle is stationary.

The custom design and packaging of commercially available parts and components is expected to be a challenge to fulfill the requirements stated within this document. The installation and integration of the auxiliary HVAC system into the MCV shall require diligent understanding, expertise with, and compliance with the base vehicle

OEM guidelines. The design effort shall require diligent coordination with customer representatives who will be completing the vehicle integrations of the specified the equipment racks. The planning and coordination among all stakeholders to assure effective and reliable cooling of the equipment racks that will be populated with Government Furnished Equipment after delivery is critical. The HVAC system’s components shall not operate beyond their published ratings, including but not limited to, pressures, volumes, temperatures, speeds, ambient, vacuums, or static pressures to obtain the required performance levels stated within. The installation shall be in accordance to the OEM Body Builder Layout Book.

All persons installing, modifying, servicing the motor vehicle air-conditioning system shall be properly trained and certified by a program authorized by the EPA. Refer to the Clean Air Act, EPA Section 609 for specific requirements of the Technician Training and Certification program.

The final configuration of the auxiliary HVAC system shall be approved by the Government at the Verification

Design Review.

Suggested sources of supply for the auxiliary HVAC system, installation, and/or validation testing are:

Proair LLC

28731 County Road 6

Elkhart, IN 46515

Phone: 574-264-5494 www.proairllc.com

Bergstrom

2390 Blackhawk Road

PO Box 6007

Rockford, IL 61125

Phone: 866-204-8570 www.bergstrominc.com

Manex Corporation

310 N Rogers road

Irving, TX 75061

Phone: 972-253-9246 www.manexcorp.com

United States Army

White Sands Test Center http://www.proairllc.com/ http://www.bergstrominc.com/ http://www.manexcorp.com/

Phone: 866-532-9767 www.wsmr.army.mil/testcenter

Offering: Auxiliary HVAC System

Offering: Testing –Validation Testing Service for Auxiliary HVAC System (refer to section 4.1)

Service provider: _______________________________________________________

Location: ________________________________________________________

3.3 AC ELECTRICAL GENERATOR, INVERTER, AND PAYLOAD BATTERY CHARGING

SYSTEM

The MCV shall have an under-hood Alternating Current (AC) electrical generator system installed in accordance with the 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.

The AC output of the AC generator and inverter shall be 120 VAC 60 Hz with frequency stability within +/-

0.2Hz and voltage and total harmonic distortion of a maximum of 5%

The AC electrical generator shall be connected to an inverter that is programmed with the appropriate charging profile for the payload batteries and charges the payload batteries when excess power is available.

When the vehicle is not running or insufficient power is being supplied through the generator system, additional power shall be supplied from the payload batteries through the inverter.

The inverter shall provide a minimum of 3.5 kW of power from the payload batteries.

The generator, inverter and payload battery charging system shall automatically switch between power sources to provide uninterrupted power to Government installed equipment on the 120 VAC output.

Components of the AC electrical generator and inverter that are mounted inside the vehicle shall be mounted at the bottom of Rack 4 and/or behind Racks 3 or 4. The height occupied by the AC electrical generator components installed in the bottom of Rack 4 shall not exceed 14 inches. The Power Control Unit (PCU) shall be mounted in the rear of the MCV behind the driver and assistant driver. The AC electrical generator shall undergo a full load test (8,000 W minimum) and inspection by the manufacturer prior to delivery and installation into the MCV.

An Electromagnetic Interference (EMI) shielded cover shall be installed over all exposed DC terminals of the inverter.

All AC power cables associated with the AC electrical generator and inverter shall be shielded to reduce EMI.

If available, an interface module/cable and software to connect a computer to the power system to monitor status shall be provided.

The installation shall be in accordance to the OEM Body Builder Layout Book. The AC electrical generator system and mounting locations for all components shall be approved by the Government at a Verification

Design Review.

The following suggested sources have been tested by the Government to ensure electromagnetic compatibility with Government installed communication systems.

Suggested sources of supply for the AC Electrical Generating System include:

Mobile Electric Power System

2714 West Kingsley Street

Garland, Texas 75041

Phone: 972-864-1015

System includes:

Generator Model: 8 kW RoadPower, 7101002, with pulley

Generator extension cable (20 ft): 591373-1120

Idle controller compatible with base MCV

Auxiliary Control Units (ACU) o Standard: 8806112-3 (PN 3806112-004 for complete system minus Inverter) o Rack Mount: 8806112-4 (PN 4806112-204 for complete system minus Inverter)

Remote Panel: 591345-6

Remote Panel Cable (15 ft): 590304-15

IGN Kit (120 VAC): 591371-7

Inverters o Outback VFX3524M or o Victron Quattro Inverter/Charger 24/8000/200-100/100

Aura Systems Inc

1310 E. Grand Avenue

El Segundo, CA 90245

Phone: 800-909-2872

System includes:

G8500XICS (Heavy Duty) with EMI filtering and shielded cables

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

Offering: AC Electrical Generator System, Inverter, and Payload Battery Charging System

Generator Manufacturer: _______________________________________________________

Rating(s):_________________________________________________________

Features:__________________________________________________________

Inverter Manufacturer: _______________________________________________________

Rating:________________________________________________________

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 49 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.

An isolation switch shall be installed between the payload battery bank and other components of the power system for safety during maintenance.

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 to provide indirect lighting of the operator compartment.

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.

An on/off switch shall be installed with all OEM dome lights

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 induced temperatures present under the hood while the vehicle is running in ambient temperatures from -32 o C to 49 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 BATTERY

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. The lights/siren system shall only draw power from the vehicle battery when the ignition switch is in the “On” or “Run” positions.

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 Layout Book.

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.

Anti-seize 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.

Electrical conductors and cables routed in conduits and looms shall be continuous in length, connections, taps, splice, terminations shall not be concealed in conduit or loom unless reviewed and approved in advance by the government.

Conductors and cables may be terminated with the electrical/electronic devices’ mating type connector or the vehicle OEM approved and released wire splice tool kit and procedures. Otherwise, the use of aftermarket butt splice, push-on (spade), bullet, ring, insulation displacement types of connectors are prohibited unless reviewed and approved in advance by the government.

Conductors and cables, rated up to 20 amperes, shall be terminated with weather pack environmentally sealed electrical connection system. Weather pack flexible pin and sleeve terminals with dual locking tangs shall be installed with calibrated ratchet type crimpers. Self-lubricating seals shall be installed on all-weather pack terminals. Connector housings shall be either in-line or panel-mount types.

3.7 SECURITY ALARM SYSTEM

A two-way security system, 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.

The installation shall be in accordance to the OEM Body Builder Layout Book.

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

Verification Design Review.

The alarm system shall be Viper, model 3303, or equal.

Offering: Alarm System

3.8 EMERGENCY LIGHTING AND PUBLIC ADDRESS/SIREN

The MCV shall be equipped with a complete all LED emergency lights, siren and PA system.

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

The emergency system shall only draw power from the vehicle battery when the ignition switch is in the “On” or “Run” positions.

The light package shall include the following components:

Console siren/light controller shall be programmable, include hand-held controller/microphone, include

PA volume adjust.

Siren: A 122dB speaker exterior rated enclosure with black epoxy coated finish.

Front Grill Lights: Encapsulated LED type with clear out lens, 5 Scan-Lock with Flash Pattern, Steady

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

Two (2) front and two (2) rear corner strobes, 90 watt/36 joule output, includes controller, Scan-Lock with flash pattern

Side and rear red and blue LED strip strobe lights

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.

Side and rear red and blue LED strip 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 installation shall be in accordance to the OEM Body Builder Layout Book, specific details are referenced in the section Design Recommendations for electrical and emergency lighting systems.

The emergency lighting and PA system and mounting locations for all components shall be approved by the

Government at a Verification Design Review.

The Emergency Lighting, Console, and PA System shall be a Whelen, HHS2200 system, or equal.

The Emergency Siren shall be a Whelen, SA314 Series (SA314B) system, or equal.

The Front Grill Lights shall be a Whelen, TIR3™ Series Super-LED® Lightheads (RS*03ZCR), or equal.

The Front& Rear Strobe Lights shall be a Whelen, S690CCCC Hideaway Strobes, or equal.

The Side & Rear Strobe LED strips shall be a HG2 Emergency Lighting, HG23TK7260XX-XX, or equal.

Offering: Emergency Lighting & PA System

Model: ________________________________________________________

Model:…