QMAA-HM-150012-D_Attachment_A_PurchaseDescription.pdf

Attachment A

Purchase Description

Field Service Truck (FST)

1.0 SCOPE

This Purchase Description (PD) is for a Field Service Truck (FST) configured with a medium heavy duty truck cab chassis, diesel driven capable of operating on JP8 with engine retarder.

The chassis shall be a crew cab, capable of transporting five personnel, one driver and four passengers.

The FST shall provide accommodations for various maintenance equipment, such as an 800 gallon diesel tank, a 100 gallon engine oil tank, a 50 gallon Automatic Transmission Fluid (ATF) tank, a 20 gallon Ethylene Glycol tank, air compressor, integrated 6KW AC generator, gas cutting and welding rig kit, heavy duty jumper cables, numerous stowage compartments for tools such as the Mechanics Tool Set and a spill/containment center. The FST shall be capable of towing a 10,000 pound trailer. Chassis, body, equipment, and accessories shall be provided as specified within this document. Operation will be on improved roads and unimproved road conditions. The operating ambient temperature range will be from –10 degree (º) Fahrenheit (F) to +130º F.

The design and integration of the system, as a whole, and all sub-systems, shall be done with full consideration of inherent human capabilities and limitations in accordance with MIL-STD-

1472G. Additionally, the engineering and design shall accommodate routine operation and maintenance to be accomplished by personnel ranging from a 5th percentile female to a 95th percentile male; utilizing DOD-HDBK-743A for percentiles.

2.0 APPLICABLE DOCUMENTS

2.1 Federal Standards and Codes

49 CFR-393 (FMCSA): Code of Federal Regulations, Federal Motor Carrier Safety

Administration, Parts and Accessories Necessary for Safe Operation

49 CFR-571 (FMVSS): Code of Federal Regulations, Federal Motor Vehicle Safety Standards

49 CFR-100-185 (FMVSS): Code of Federal Regulations, Federal Motor Vehicle Safety

Standards, Transportation

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.

http://www.access.gpo.gov/

DoD-HDBK-743A (13FEB91): Department of Defense Handbook, Anthropometry of

US Military Personnel

MIL-STD-1472G (11JAN12): Military Standard, DoD Design Criteria Standard Human

Engineering

2.2 National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

Application for copies of the standard should apply to NFPA, 1 Batterymarch Park, PO Box

9101, Quincy, MA 02269-9101

2.3 Society of Automotive Engineers, Inc.

J689: Approach, Departure, and Ramp Breakover Angles.

J682: Rear Wheel Splash and Stone Throw Protection.

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

J516: Hydraulic Hose Fittings

J517: Hydraulic Hose

J537: Storage Batteries

J704: Openings for Six and Eight Bolt Truck Transmission Mounted Power Take-Offs

Applications for copies of SAE publications should be addressed to SAE, Inc., 400

Commonwealth Drive, Warrendale, PA 15096.

2.4 Other Standards

RP 803: Pre-Service Vehicle Inspection

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

2.5 Order of Precedence

In the event of a conflict between the text of this purchase description and the references cited above, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

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

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. 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 offeror shall have documented quality assurance processes to assure compliance with all specification requirements including requirements established by reference; i.e. SAE, FMVSS, etc. Successful Offeror shall submit, with their offer, a copy of their documented processes or procedures.

The offeror (manufacturer) who responds to this solicitation shall have a minimum of five years of engineering, design, and manufacturing experience in providing similar vehicles with equal or greater complexity to the requirements described herein. The offeror shall have 24 hour/ 7 days per week access to customer service. The offeror shall provide detailed information describing their customer service access.

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

3.1 Chassis

A 2015 or current model year Freightliner M2-106, Crew Cab, 4x2, model or equal vehicle shall be furnished with the Original Equipment Manufacturer (OEM) options listed below. If another chassis is offered, that chassis shall be supplied with trim and option levels equal to those described below. The Successful Offeror shall provide a copy of the technical sales order to

GSA as soon as the order is placed for review. The Successful Offeror shall weigh the chassis, filled with fuel, as soon as it is available and provide GSA with the information before any modifications are done.

OFFERING

Chassis: ___________________________________________________

Manufacturer: ______________________________________________

Model: _____________________________________________________

Engine Make/Model: _________________________________________

Engine Torque/HP: __________________________________________

Transmission Make/Model/Speed: _____________________________

Vehicle Configuration

Freightliner M2-106 chassis, or equal

2015 Model Year or current Model Year chassis available for sale when the order is placed

Domiciled, USA (excluding California and CARB opt-in states)

Crew Cab

Straight truck provision

LH primary steering position

General Service Rugged Duty Service

Minimum speed 25MPH @ maximum 5% grade while pulling a 10,000 pound trailer

Engine

EPA National Security Exempt engine

JP8 capable

High sulfur diesel capable

Vertical exhaust

Engine Equipment

Engine mount check oil and fill

Air cleaner mounted in engine compartment

Minimum 200 Ampere Alternator

Three 12 volt maintenance free batteries, group 31, 3375 CCA minimum

Single battery box

Master Battery Disconnect Switch

Positive and Negative posts for jump start

15.5 CFM air compressor

Engine compression and exhaust brake

Full flow oil filter

Engine coolant to -34 degrees F

Engine block heater

Fan clutch

Heavy duty starter

Transmission

Allison 3500 RDS 6 speed automatic transmission with PTO provision

Transynd Synthetic fluid

Transmission Equipment

Push button electronic shift control, dash mounted

Water to Oil transmission cooler, frame mounted

Transmission oil check and fill with electronic level check

Magnetic plugs, engine drain, transmission drain, axle fill and drain

Front Axle and Equipment

16,000 pound rating (minimum)

Set back axle

Heavy Duty , non-asbestos lining

Brake drums

Dust shields

Long-stroke brake chambers

Automatic slack adjusters

Standard spindle nuts

Power steering

Front Suspension

16,000 pound tapered leaf (minimum)

Shock absorbers

Rear Axle and Equipment

23,000 pound rating (minimum)

5.5 ratio minimum

Heavy Duty , non-asbestos lining

Brake drums

Dust shields

Long-stroke brake chambers

Automatic slack adjusters

Standard spindle nuts

Oil seals

Rear Suspension 23,000 pound multi-leaf spring (minimum)

Stabilizer bar

Brake System

Dual air

Anti-Lock Braking System (ABS)

Automatic Traction Control (ATC)

Brake line drier with heater

Air dryer with replaceable desiccant cartridge

Steel air reservoirs mounted inside rails

Auto drain valve without heater to wet tank

Drain valve cables on all other tanks

Air connection to end of frame with glad hands

SAE J560 7-way connector at end of frame

Wheelbase & Frame

Wheelbase as required for body

102 inch cab to axle (CA) minimum

Rear frame overhang as required for body

Bumper extension front

Chassis Equipment

Front bumper full width

Front tow hooks, (2) frame mounted

Front license plate below bumper

Black mud flap brackets

Fuel Tanks

100 gallon minimum capacity

RH / LH, 50 gallon tanks

Fuel tanks forward

Fuel tank steps

Fuel filter /water separator

Fuel tank equalizer flow control

Tires

Front and Rear 18 Ply Radial (minimum), Mud & Snow

Tires shall be of the tubeless type

Tires shall be of rated capacity no less than specified max vehicle GVW

Tires shall conform to the Tire and Rim Association recommendations

Tire shall be rated for highway speeds at maximum GVWR

One Spare Tire Assembly shall be provided; the spare shall match the mounted tires

One spare tire carrier shall be provided - may be integrated into body

Tools, tire removal/installation and jack shall be provided

Hubs

OEM standard front hubs

OEM standard rear hubs

Wheels

OEM standard color: OEM Dark Blue

Cab Exterior

Crew Cab

LH and RH interior grab rails

Fiberglass hood

Grill to be standard OEM as offered on base model truck

Hood & Tunnel/Firewall Premium noise abatement and insulation

Air horn

Electric horn

Back-Up alarm

Day Time Running lights

Dual west coast bright finish heated mirrors with integral convex and dual axis LH/RH remote

Door mounted mirrors

Minimum 96 inch equipment width

RH down view mirror

RH & LH fender mounted bright finish mirrors with bipod brackets

Tinted door glass, LH & RH

Tinted windshield

Cab Interior

Black or Dark Grey vinyl interior

Gray dash

Black floor mats

Vinyl carpet/door trim

Forward roof mounted console

Two cup holders at dash area

Heater, defroster, and air conditioner with constant outlet temperature control

High capacity AC system

Heavy Duty air conditioner compressor

Radiator mounted AC condenser

Standard heater plumbing

Door activated dome light

High back air suspension driver and front passenger seats

Three point adjustable retractor driver and front passenger seat belt

Three passenger bench seating for rear position

Three point adjustable retractor rear outboard positions, lap-belt center position

Adjustable tilt and telescopic steering column

Driver and passenger sun visors

Instruments & Controls

Standard gauge package

Black bezels

Black instrument panel and center console

Key operated ignition switch

Electronic cruise control

Low air pressure light and buzzer

One single brake application air gauge

Primary and secondary air pressure gauges

Dash mounted air restriction indicator with graduations

Key operated ignition switch

Odometer/Trip/Hour/Diagnostic/Voltage display

Diagnostic interface connector, 9 PIN, SAE J1587/1708/1939, Electric fuel gauge

Electric engine coolant temperature gauge

Electric engine oil pressure gauge

Transmission oil temperature gauge

Engine and trip hour meter

Electronic MPH speedometer with secondary KM/H scale

Electronic tachometer

Electric windshield wiper with switch

Marker light/headlight switch

Turn signal switch

Overhead instrument panel

AM/FM/CD radio dash mounted

Two radio speakers in cab

Citizen Band prep package

Power and ground wiring provisions

Multi- band Citizen Band radio, 40-channel, headliner mounted; dual mirror mounted antenna system

400 Watt, 12VDC to 120VAC inverter with two outlets

Color

Cab Color: OEM Dark Blue

Black, high solids polyurethane chassis (frame) paint

3.1.1 Rear Towing Provisions

The vehicle shall be equipped with rear towing provisions for trailers up to 10,000 pounds. The provisions require a 2-1/2 inch square hitch receiver with locking hitch pin assembly with three keys, adjustable pintle height, 2-5/16-inch combination hitch with a 16,000 pounds pintle, a ball rating of 14,000 pounds, and a 3,000 pounds vertical load limit.

The trailer towing package shall consist of the combination hitch with ground height, of 20 to 25 inches, safety chain attachment devices, a 7 round pin conforming to SAE J560 and 7 flat pin

(RV type) lighting receptacles and associated reinforcements and wiring shall be installed on the rear of the vehicle.

A conspicuous label shall be located near the hitch stating the rated capacity of the hitch and other pertinent information requiring proper hookup and use. This hitch must be able to accept a lunette measuring not less than 3-inches round and 1.66-inches thick.

3.1.2 Payload Capacity

The payload capacity of the completed vehicle shall be a minimum of 10,000 pounds. Payload shall include supplies, equipment, driver and four passengers at 220 pounds each, and the specified fluid capacities.

Curb weight shall include the complete finished vehicle as specified herein including full fuel tank and all attached equipment, PTO, generators, body, tanks, hose reels, etc. Vehicle as completed, in road travel configuration (full curb weight, including full fuel tank, chassis fluid tanks, all mounted equipment, and 10,000 pounds payload, shall be below the GAWR at each axle and below the GVWR overall.

As part of the bid an engineering estimate of vehicle curb weight with proposed equipment added shall be provided as well as weight distribution estimates to insure GVWR and GAWR are maintained within manufacturers’ guidelines. Detailed drawings showing weights and distribution calculations shall be provided at the vehicle design reviews.

3.2 Body Requirements

The body shall be steel construction. The FST shall be capable of operating in austere conditions. The vehicle’s exterior finished surfaces will be coated to minimize corrosion in salt-air environments.

The maximum body exterior width shall not exceed 96 inches. The minimum length of the body shall be 14 feet. The maximum height of the vehicle shall be 13 feet to the top of any structures permanently mounted to the roof in road ready condition.

A drawing of the vehicle shall be provided with the offer showing interior and exterior views. A boundary layer material providing galvanic protection shall be placed between aluminum and steel components as required. Detailed drawings showing layout and provisions shall be provided at the vehicle design reviews. The final vehicle layout shall be approved by the GSA and the Navy at the Critical Design Review (CDR).

The rear departure angle of the completed vehicle shall not be less than 10 degrees.

3.2.1 Body Mounting

The body shall be attached to the chassis rails in accordance to the OEM instructions and shall be suitable for severe service duty as described within these requirements. Shock and vibration isolation solutions shall be installed between the body and the chassis frame.

3.2.2 Body Construction and Undercoating

The body shall be of the open type; for the purpose of this project, open type body means side walls with no roof. Under floor cross members shall be tied together with longitudinal structural members. All body structural sections shall be welded together. The exterior skin shall be a minimum of 12 gauge galvanized steel. The rear hose enclosure shall include a roll up door.

The body access doors shall be a minimum of 14 gauge galvanized steel, provided with rotary latches, and stainless steel hinges. The decking surfaces shall be constructed of diamond plate.

All joints and seams on the body and doors shall be sealed and weather proofed.

The intent and purpose of the specified body is to provide storage provisions for Government

Furnished Equipment (GFE) and/or conceal the specified equipment/tanks mounted on the deck.

Depending upon final design, body sidewall sections or other forms of access service doors shall be required to fill in the voids between storage cabinets.

The vehicle shall be undercoated for sound deadening, corrosion and stone damage protection.

A commercial, fire resistant, petroleum base or rubberized undercoating, or other material providing equivalent protection, shall be spray applied to the underbody and under chassis sheet metal surfaces to a thickness of 1/16 to 1/8 inch, except to the drive shafts, drain holes, lubrication points, engine/transmission oil pans, fuel tanks, heavy castings, suspension components, heat shields and areas within 12 inches or less from exhaust system components, as well as other areas specifically excluded by the chassis manufacturer. These areas shall be kept free of undercoating.

The chassis frame, underside of the engine compartment hood, and underbody surfaces in excess of 1/8 inch thickness, or that are inaccessible without removing vehicle fuel tank(s) or other major components, shall not require undercoating.

Storage provisions shall be in a vehicle body side compartment and they shall be accessible from ground level.

Government furnished tool kit shall store within vehicle’s body storage provisions. The top of the GFE Mechanics Tool Kit located in the storage cabinets shall not exceed 54 inches above grade.

Detailed drawings showing layout and body and storage provisions shall be provided at the vehicle design reviews. The final vehicle layout shall be approved by the GSA and the Navy at the CDR.

3.3 Body Up-fitting Requirements

The FST body shall be configured with the following provisions:

Diesel fuel tank

Engine oil tank

Automatic transmission fluid (ATF) tank

Ethylene Glycol tank

Air compressor

Hydraulic operated electric generator/welder

12 VDC jump starting provisions

Gas cutting and welding rig

The electric generator, welder, and air compressor may be a single multi-function unit depending upon layout and packaging provisions.

The specified tanks shall:

be capable of being filled from the top and a quick fill coupling system.

be equipped with automatic pumping/dispensing systems compatible with the specified fluids.

include fluid level sensing, with respective display located at dispensing point.

include a pumping systems with all piping, valves, controls, high pressure filters, and retractable hose reels (minimum 50’ length).

In addition to the fluid level sensing displayed at the dispensing point, the fuel tank shall come equipped with an analog type level gauge; sight glass is not permissible.

The hose reels shall be located at the rear of the body.

A filter drain box shall be provided in the hose reel compartment.

3.3.1 Diesel Fuel Tank and Dispensing

One 800 gallon minimum diesel fuel tank shall be provided. The rectangular tank shall be constructed of steel and installed within the body.

The following provisions shall be provided:

One 20GPM @ 50-PSI minimum free flow pump system

One fuel meter (0-50GPM)

One dual head 100GPM fuel filter

One spring rewind 1” x 50’ hose and ball-stop reel

One 1” swivel automatic diesel fuel nozzle

Fluid level sensing, with respective display located at dispensing point

Analog type level gauge, sight glass not permissible

One permanent assist step assembly, mounted on the rear tank wall closest to the manual fill neck on top of tank, allowing operator to manually fill the tank

One manual fill neck with cap on top of tank, curbside, allowing operator to fill tank at retail fueling stations

Hose reel to be labeled Diesel Fuel/JP-8

3.3.2 Oil Tank and Dispensing

One 100 gallon minimum oil tank shall be provided. The rectangular tank shall be constructed of steel and installed within the body.

One air operated pump systems, minimum 10:1 ratio

One air regulator

One air installation kit

One spring rewind 1/2” x 50’ hose and ball-stop reel

One 1/2” rigid extension quick nozzles rated at minimum of 14GPM

One electronic preset dispensing meter

Fluid level sensing, with respective display located at dispensing point

One reel to be labeled (Engine Oil)

3.3.3 Automatic Transmission Fluid Tank and Dispensing

One 50 gallon minimum ATF fluid tank shall be provided. The rectangular tank shall be

One air operated pump system, minimum 10:1 ratio

One air regulator

One air installation kit

One spring rewind 1/2” x 50’ hose and ball-stop reel

One 1/2” rigid extension quick nozzle rated at minimum of 14GPM

One electronic preset dispensing meter

Hose reel to be labeled ATF

3.3.4 Ethylene Glycol/Coolant Tanks and Dispensing

One 20 gallon minimum coolant fluid tank shall be provided. The rectangular tank shall be

One air operated pump systems, minimum 10:1 ratio

One air regulator

One air installation kit

One spring rewind 1/2” x 50’ hose and ball-stop reel

One 1/2” rigid extension quick nozzle

One reel to be labeled (Anti-Freeze)

3.3.5 Air Compressor

One air compressor shall be provided.

One hydraulic operated compressor rated at 40CFM @ 100PSI minimum

One hydraulic plumbing

One 20 gallon minimum reservoir for piston compressor, or a minimum of 4 gallon reservoir for rotary screw type compressor

One air separator/regulator/lubricator

One air compressor installation kit

One spring rewind 1/2” x 50’ hose and ball-stop reel

One 1/2” rigid extension quick nozzle

One removable cover for use during storage with restraints to preclude loss during transport

3.3.6 Electric Generator

One electric generator shall be provided.

One hydraulic operated electric generator rated at a minimum of 6000 Watts, 240/120VAC, 60Hz

One hydraulic plumbing

One 240V 20A outlet twist lock

Two 120VAC 20A duplex outlets with GFCI

Two 50’ extension cords, #12AWG, with single NEMA outlet

Location: shall not be mounted in rear reel area

3.3.7 Welding Provisions

One welding rig shall be provided.

One hydraulic operated DC welder rated at a minimum of 250 Amperes continuous duty cycle output

One hydraulic plumbing

One 120VAC outlet

One 240VAC outlet with 50’ long cables

The welding system, electric generator, and air compressor may be a multi-function unit depending upon layout

Final configuration and location of the welding rig with 120V and 240V outlets shall be approved by the Government.

3.3.8 12VDC Jump Starting Provisions

The following jump starting provisions shall be provided:

Utilize the chassis batteries

Heavy Duty 800 Ampere quick connect plug, socket, clamps, cable assembly

#1/0 AWG minimum duplex welding cable with clamps and quick disconnect plug, 30 feet length

#1/0 AWG minimum cables connected to chassis batteries, length as required

Polarity protection on quick connector/socket assembly

Mating socket for quick connector in weatherproof housing shall be mounted on the body

3.3.9 Provisions for Government Furnished Equipment (GFE)

All GFE shall be delivered to the place of performance no later than 20 days After Receipt of

Order (ARO).

3.3.9.1 Cutting Equipment

One Gas Cutting Kit and Welding Rig (NSN 5180-LL-LC3-8083) shall be provided as GFE.

Storage provisions for the GFE shall be located on the rear deck or in side compartment.

Dimensions are approximately 57 inches length x 33 inches width x 43 inches height. Total weight of Gas Cutting Kit and Welding Rig is approximately 281 pounds, including the gas bottle cart.

The Successful Offeror shall provide provision on or in the body to secure the cutting and welding rig.

3.3.9.2 Mechanics Tool Kits

One Mechanics Tool Kit Expeditionary (NSN 5180-LL-LCC-4220, Grainger Part No. 80013V) with two storage cabinets shall be provided as GFE.

Storage provisions shall be in a vehicle body side compartment accessible from ground level.

When set in the vehicle the top of the GFE Mechanics Tool Kit, located in the storage cabinets, shall not exceed 54 inches above grade.

Standard and metric tools are included in the GFE. The tool storage cabinets are approximately

34 inches wide x 17 inches deep x 30 inches height each. Total weight is approximately 375 pounds.

3.3.9.3 Hazardous Spill Containment Kit

One Spill Containment Kit (NSN 4235-01-387-1381) shall be provided as GFE. Storage provisions shall be located on the rear deck or in side compartment. The kit is portable and is approximately 48 inches length x 72 inches width x 12 inches height.

3.3.9.4 Narrow Band Radio and Antenna

One FM narrow band radio and antenna will be provided as GFE. The Successful Offeror shall provide provisions for the radio and antenna. The Successful Offeror shall install the radio in the cab and the antenna on the side view mirror. If determined that mirror placement is detrimental to the equipment, the Successful Offeror can suggest different placement at CDR, Government has final say on placement.

3.3.9.5 Storage Provisions for Spare Parts Kits

Storage provisions for vehicle spare parts, filters, etc… shall be provided in the body storage compartment(s). The location, identification, configuration, allocation, and use of all available storage compartments shall be approved by the GSA and the Navy at the second CDR (Critical

Design Review) meeting.

3.4 Hydraulic System General Requirements

The following requirements shall apply to the hydraulic systems installed on the FST.

3.4.1 Drive systems.

Hydraulic pumps shall be driven by one of the following:

Engine or transmission mounted Power Take-Off (PTO). Pumps shall be flange mounted for transmission mounted PTO. Belt drives of any type are not acceptable and shall not be used.

Engine crankshaft front PTO driven. Only OEM integral frame extensions and OEM approved and furnished chassis for front PTO shall be used.

Pump support brackets shall be installed from the transmission to support the pump(s) if the combined weight of the pump(s), hoses, and fittings exceed 40 lbs., of if the combined length of the PTO and pump(s) exceeds 18 inches measured form the center-line of the PTO to the end of the pump(s).

PTO’s shall be rated at a minimum of 150% of the maximum horsepower requirement of the hydraulic system. The minimum PTO horsepower rating shall be calculated by the following formula:

85.1714

50.1

PV

= Minimum PTO HP Rating

Where P = max working pressure in PSI and V = max flow in GPM

PTO’s shall be of the power shift design. PTO shift controls shall be electric-over-hydraulic for automatic transmissions and air shift controls for air braked chassis. There shall be a PTO engagement indicator located in the truck cab, in close proximity to control switch. Over speed engagement protection shall be furnished. PTO shall disengage when pre-set engine RPM is reached.

The torque or horsepower required of the hydraulic drive PTO shall not exceed the maximum torque or horsepower rating of the PTO opening on the transmission or PTO drive pad on the engine or engine crankshaft.

All PTO’s shall be installed within the backlash recommendations of the PTO manufacturer.

3.4.2 Hydraulic system hoses, fittings, pressures, and flow rates.

Hydraulic hoses shall be rubber covered double wire braid reinforced and comply with SAE

100R2, Type A or AT, or 100R9, type A or AT, of SAE J517. The working pressure of the hose shall exceed the pressure setting of the relief valve.

Hoses shall be sized such that the maximum velocity of hydraulic fluid in the hose does not exceed the following:

Fluid velocity in suction lines shall not exceed 4 ft/sec.

Fluid velocity in discharge lines shall not exceed 25 ft/sec

All hoses shall be installed in accordance with the requirements and recommendations of SAE

J1273

System working pressures shall not exceed the maximum pressure of the powered devices or

3500 PSI. A system pressure test port shall be provided. The test port shall be located so that the maximum pressure produced by the system can be monitored without disconnecting any component of the system.

Hydraulic hose fittings shall comply with the requirements of SAE J516 for permanently attached (crimped) fittings with JIC 37° flare. Field replaceable type fittings are not acceptable.

Forged steel hydraulic adapters shall be used. Cast steel fittings are not acceptable.

3.4.3 Pressure protection.

All hydraulic systems shall be furnished with either a spring or pilot actuated pressure relief valve. The relief valve shall be used for overpressure protection only and shall not be used for any flow control purpose. In no case shall a relief valve be set at a pressure higher than the working pressure of the lowest rated component (hose, coupler, adapter, cylinder, etc.) in the system.

3.4.4 Flow control valves.

Flow control valves shall be of a type (such as open-center valves) that assures that hydraulic fluid is never deadheaded and forced to flow over the relief valve. Flow control valves shall be expandable to control multiple devices, either in parallel or in series. Series designed systems shall not exceed the maximum working pressure of any component in the series. Flow control valve body shall not be mounted inside the cab. Flow control valves shall be operated through leavers mounted inside the cab within easy reach of the seated driver. Control leavers shall operate flow control valves through flexible cables or air pressure and permit smooth, infinitely variable operation of equipment through the full designed range of operational travel/speed limits of the equipment.

3.4.5 Fluid filtration.

A return line hydraulic filter shall be furnished having a minimum efficiency rating of 99% down to 10-micron size particles and meet or exceed the filtration requirements of the pump, motor, or driven device manufacturer. The filter shall be furnished with a pressure differential type service gage or service indicator.

3.4.6 Hydraulic system cooling.

Hydraulic systems shall be designed to operate in ambient temperatures ranging from –10 º F to

+130º F.

The hydraulic system shall be designed such that the maximum hydraulic oil temperature does not exceed 200º F. For continuously driven devices, such as motor driven applications, auxiliary cooling, such as air-to-oil coolers or water-to-oil coolers, shall be furnished if required to meet the maximum oil temperature requirement.

The Government reserves the right to request and be furnished test documents showing maximum stabilized temperatures of hydraulic systems.

3.4.7 Hydraulic reservoir.

A stainless steel, aluminum, plastic, or other non-corroding type hydraulic reservoir shall be furnished and sized such that the reservoir working volume is a minimum of 150% of the maximum hydraulic flow rate.

The reservoir shall be furnished with the following:

The reservoir shall be furnished with a baffle separating the suction from the return flow.

The reservoir shall be furnished with minimum 3/4 inch air filtration type breather or combination breather cap with not greater than 10-micron air born particle rating.

The reservoir shall be furnished with a drain plug located at the bottom of the tank for draining oil.

The reservoir shall be furnished with a metal enclosed and protected sight glass for observing oil level.

The reservoir shall be furnished with a maximum 300 mesh (50 micron) fill strainer.

The reservoir shall incorporate a return tube that discharges return oil below the surface of the reservoir oil.

3.4.8 Hydraulic oil.

Hydraulic oils shall meet the minimum requirements of the hydraulic pump or other critical component manufacturer(s). Water based hydraulic fluids shall not be used. A nameplate shall be affixed near the fill cap on the reservoir indicating the type of oil to be used.

3.4.9 Installation and workmanship.

The hydraulic system shall comply with the following requirements:

All tapered threaded fittings shall be installed using an anti-seize thread sealing compound.

Teflon tape is not acceptable.

Hoses shall be routed for easy tracing of hoses and shall be protected with grommets when passing through bulkheads. Hoses shall be protected from abrasion when routed over or through bare metal edges.

Hydraulic hoses shall be supported with metal hose clamps that provide protection for the hose from the metal portion of the clamp. Hoses shall not be allowed to droop or to be entangled with other hoses or lines. The clamps shall be spaced not more than 18 inches apart.

Overhanging weight of fittings, hoses, valves, or piping shall be supported from the reservoir to eliminate flexing of sidewalls.

All hoses shall be routed and installed in accordance with the requirements and recommendations of SAE J1273. Special attention to routing and installation shall be given to avoid the following:

Tensile loads on the hose

Side loads

Flattening

Kinking

Thread damage

Damage to sealing surfaces

Abrasion

Twisting

Exceeding minimum hose bend radius

3.4.10 Operational Test

The hydraulic system and hydraulically driven components shall be operated and checked for leaks and proper operation. The operational test shall include the maximum requirements

(height, extension, speed, etc.) of the driven devices under no-load conditions. No leakage is permitted beyond a class “1” leak in accordance with SAE J1176-External Leakage

Classifications for Hydraulic Systems.

3.5 Rear Bumper, and Wheel Well Molding

The rear of the vehicle shall be furnished with a full-width bumper, secured to the vehicle’s chassis frame. The ends of the bumper shall not extend past the width of the body. The bumper shall not extend below the body and shall not interfere with the 10 degree departure angle.

Exterior wheel well splash moldings shall be furnished at the axles and shall be pre-molded to conform to the wheel well cutouts.

3.6 Amber Beacon

The vehicle shall be equipped with an amber warning beacon mounted on top of the chassis cab.

All equipment shall be installed in full compliance with manufacturer's guidelines and recommendations. Final approval of the warning light system shall be decided at the verification design review.

3.7 Electrical System, 12 VDC

The 12-volt system shall consist of two branches as follows: one branch shall power the OEM chassis components, equipment, accessories and Federal Motor Vehicle Safety Standard

(FMVSS) lighting; the other branch shall utilize deep cycle batteries for powering 12-volt equipment and accessories associated with the utility portion of the vehicle’s mission, including lighting, etc. The batteries associated with both branches shall be charged by the cab-chassis vehicle engine alternator. The 12-volt electrical system shall include the following: wiring, main distribution panel board, batteries, branch circuits, and lighting as specified herein.

3.7.1 Wiring

All 12-volt wiring shall be in accordance with the applicable portion of SAE J1292. All 12-volt wiring mounted to the chassis or outside the body shall be stranded and have SXL type insulation. All conductors shall be stranded copper. All 12-volt wire shall be routed in flexible loom or conduit. Wiring terminals used in all 12-volt wiring shall grip the wire insulation as well as the conductor. All fasteners, conduit, conduit fittings, shall not exhibit electrolysis with adjacent materials. All exterior lighting shall be wired within the body to the exterior lights.

Wire shall be accessible for replacement without removing any component of the vehicle. Wire shall be capable of being replaced and serviced through the conduit and junction boxes.

Grommets or electrical bulkhead fittings shall be employed for any wire passing through structural member(s). All 12-volt wire shall be color-coded as specified in SAE J560. The 12

VDC panel shall include a digital voltmeter and low voltage alarm, which activates at 12.5 volts.

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

3.7.2 Lighting

All exterior Federal Motor Vehicle Safety Standard (FMVSS) lighting shall be in accordance with Federal Motor Vehicle Safety Standard (FMVSS) 108 (49 CFR 571.108). All lamps except

OEM lights shall be LED type and shall be mounted in recessed locations or guarded to provide protection from operational, except lower rear marker lamps and ABS light. The stop, turn and tail lamps shall be mounted onto the rear of the body. The vehicle shall be furnished with conspicuity markings in accordance with Federal Motor Vehicle Safety Standard (FMVSS) 108

(49 CFR 571.108).

Four 12VDC, 65 Watt high intensity flood lights shall be installed on the body. The flood lights shall be mounted to the body as follows: two on the rear corners both street and curb sides, two at the forward corners both street and curb sides.

The floodlights shall be hardwired with remote controlled (individually) with pan and tilt adjustments. The remote controls shall be centrally located.

The lights shall be Magnalight Golight model GL-30212-32C, or equal.

The remote controls for the two front flood lights shall be mounted in the vehicle cabin adjacent to the FST body controls.

The remote controls for the two rear flood lights shall be mounted in the vehicle rear hose reel cabinet.

Two 12VDC service lights shall be installed on the interior section of the body. The service lights shall be able to be switched on/off manually. Final location of the lights and switches shall be approved by the Government.

3.7.3 Batteries

All batteries shall be installed underbody in a weather resistant compartment(s) with a locking cover or lid that is either removable or opens to give full and easy access to the batteries. The battery system provided shall be accessible to the operator when standing on the ground surface for inspection and servicing. The specified Master Battery Disconnect Switch (MBDS) shall disconnect all OEM accessory loads and all aftermarket connected loads, less connection of any mandatory OEM CPUs/ECUs. The intent of the MBDS is to minimize parasitic loss during storage.

3.8 Electrical System, 240/120 VAC

The vehicle body’s Alternating Current (AC) electrical system shall be in accordance with the

National Electrical Code (NEC). The vehicle shall be equipped with a 240/120-volt, single phase, 60 Hz, 4-wire electrical system. The electrical system supply shall be from the on-board hydraulic PTO engine generator.

The system shall consist of the following:

Wiring

Conduits

Branch circuits

Circuit breakers

Receptacles

3.8.1 Wiring and Distribution

The vehicle shall be wired from a central distribution point (location to be determined at the

CDR). All wiring and cable conductors shall be stranded copper and THHN insulation. Wiring shall be color coded at the junction boxes and at the main distribution panel board for identification purposes. It is not acceptable for any wiring to pass over a sharp edge. Wiring shall be of sufficient size and gauge to carry 125% of the current imposed in operating the electrical system without loss of dielectric strength. All receptacles shall be of the GFCI protected type. The 120VAC receptacles shall be (NEMA 5-20R) black duplex outlet 120VAC, 20 amp exterior grade duplex electrical receptacles. The 240VAC receptacle shall be (NEMA

L6-20R) 240VAC, 20A black twist-lock.

3.9 Retractable Service Lighting, 120VAC/12VDC

One heavy-duty cord reel 120VAC 50 feet with 13 watt minimum fluorescent rated trouble light and utility outlet shall be installed in the rear compartment on the truck.

One heavy duty cord reel 12VDC LED light shall be installed in the rear compartment of the truck. The light reels shall be connected to the specified electrical systems. The 12VDC light will be able to be used with truck not running.

The cord reels shall be Grainger part number 2XJA8, Reelcraft model L405016381, or equal.

Final configuration and location of the cable reels with service lights shall be approved by the

Government.

3.10 Fire Extinguisher / Safety Triangles / Hazmat Placards

Two five pound ABC-type fire extinguisher shall be furnished and mounted one each area of the body. Location to be determined at the post contract award meeting.

A set of three reflective safety triangles will be shipped loose with the vehicle.

The vehicle shall have Department of Transportation (DOT) Hazmat Placards or NFPA 704

Hazard Warning Diamonds As outlined in 49 CFR 172. The DOT mandates that markings be used when transporting hazardous materials and dangerous goods in the United States.

3.11 Keys

Three sets of keys shall be furnished for every lock on the vehicle. All storage compartments shall be keyed alike.

3.12 Marking, Data, and Plates

A permanent aluminum or plastic plate, indicating the name of the manufacturer; vehicle type;

year and model number; warranty expiration date (month and year); manufacturer's vehicle identification numbers and vehicle dimensions, including overall height, width, length, and

GVW, shall be permanently affixed to the vehicle in one of the following locations: inside the glove box door; or on the driver's side door post. Actual location shall be subject to the approval of the Government. Data shall be permanent.

3.13 GSA Form 1398

Unless otherwise specified, the Successful Offeror shall affix one copy of GSA Form 1398, GSA

Purchased Vehicle, fully completed, to the right or left front door lock face or door post after final inspection is made. All marks on windows and other labels (except labels cautioning against drained transmission, crankcase, and rear axle) shall be removed. Copies of GSA Form

1398 are available from the Contracting Officer.

3.14 Operator’s Servicing and Parts Manuals

One chassis OEM operator’s manual and full shop parts and service manuals for the vehicle chassis shall be furnished with the vehicle, in both hard copy and electronic formats. In addition, operating manuals for all body installed equipment/systems and components shall be furnished with each vehicle.

Literature shall include all systems and component items furnished on the vehicle including but not limited to the following: the Operator’s Manual, Service Manual, Parts Catalog, Lubrication

Charts, hydraulic system, generator system, converter, breaker panel, lighting components, a/c system, heater system, and any other component furnished.

The service manuals shall include 12VDC and 115VAC as built wiring diagrams. All body, sub-systems, and equipment requirements described above shall be provided in both hard copy and electronic formats.

3.15 Exterior Paint, Graphics, and Decals

The vehicle and body exterior shall be painted with a standard chassis OEM Dark Blue. All primer and paint applications shall comply with the paint manufacturer’s application instructions and recommendations.

The Successful Offeror shall be responsible for providing and installing decals and custom painted lettering, including agency seals and vehicle identification information, on the vehicle.

Final design and placement of all decals and graphics will be at the direction and approval of the

Government.

3.16 Workmanship

Vehicles shall be free from defects that may impair their serviceability or detract from appearance.

All bodies, systems, equipment and interfaces with the chassis shall be done in accordance with the OEM’s Body Builders Book. Whenever dissimilar metals are used, they shall be insulated against corrosive action.

All components shall be new. Defective components shall not be furnished. Parts, equipment, and assemblies, which have been repaired or modified to overcome deficiencies, shall not be furnished without the approval of the purchaser. 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. General appearance of the vehicle shall not show any evidence of poor workmanship.

The following shall be reason for rejection:

Rough, sharp or unfinished edges, burrs, seams, corners, and joints.

Non-uniform panels. Edges that are not radiused, beveled, etc.

Paint runs, sags, orange peel, “fish eyes ”, etc.., and any other imperfection or lack of complete coverage of paints or coatings.

Body panels or components that are uneven, unsealed, or contain cracks, dents or have voids.

Misalignment of body fasteners, glass, viewing panels, light housings, other items with large or uneven gaps, spacing etc. such as door, body panels and hinged panels.

Improperly fabricated and routed wiring or harnesses, and electrical connections.

Improperly supported or secured hoses, wiring harnesses, mechanical controls etc., including interference with other components.

Interference of chassis components, body parts, doors, etc.

Leaks of any gas, vacuum, or fluid lines (air conditioning, coolant, oil, etc.).

Noise, panel vibrations etc.

Inappropriate or incorrect use of hardware, fasteners, components, or methods of construction.

Incomplete or improper welding, riveting or bolting.

Lack of uniformity and symmetry where applicable.

Loose, vibrating, abrading body parts, components, subassemblies, hoses, wiring harnesses or trim.

Improper body design or interface with the chassis that could cause injury during normal use or maintenance, and which fail to provide access to perform routine or mandatory repairs or maintenance on vehicle electrical and mechanical systems. In addition, the improper combination of options which by their combination and installation are inherently incompatible with regard to function or safety.

Sagging non-form fitting upholstery or padding, holes, tears, discoloration, etc.

Incomplete or incorrect application of rust proofing.

Visual deformities and equipment malfunctions.

Unsealed appurtenances or other body components, gaskets, etc. The door openings on body storage compartments include gaskets.

In addition, any deviation from specification requirements or any other item, whether or not stipulated herein, that affects form, fit, function, finish, durability, reliability, safety, performance or appearance shall be cause for rejection.

3.17 Verification Requirements

The Successful Offeror shall verify compliance to the requirements herein prior to first vehicle production release, based on the following verification matrix. Verification may be in the form of Successful Offeror production line bill of material, drawings, instructions, test results, vendor documentation, certifications, or design analytical data. The Successful Offeror shall not proceed with production before receiving agreement from the Government that verification of compliance is satisfactory. Acceptance of designs by the Government does not relieve the

Successful Offeror from the Successful Offeror’s responsibility to meet all the requirements and specifications herein, whether reviewed by the Government or not. It shall be the Successful

Offeror’s responsibility to assure all production documentation results in the production of vehicles that are in compliance with these requirements and specifications.

PAC Post Award Conference Contract Award + 7 Days

PDR Preliminary Design Review Contract Award + 45 Days

CDR Critical Design Review Contract Award + 90 Days

FVI First Vehicle Inspection

BOM Bill of Material

The type of verification to be submitted for acceptance is listed below:

ET Engineering Test – to be performed by the Successful Offeror and results accepted by the

Government. Engineering tests are tests resulting in data output from engineering instruments used to take measurements of parameters such as temperatures, sound levels, etc. Verification may be in the form of an engineering report, test result sheet, or test summary with results documented.

COC Confirmation of Compliance – Validation by analysis or production builds documentation to be performed by the Successful Offeror and submitted for acceptance by the Government.

Verification may be in the form of analysis summaries, build documentation, purchase orders, or similar written documentation.

QAPVT Quality Assurance Performance and Verification Testing – Testing to be performed and verified by the Successful Offeror to the Government. QAPVT tests are functional tests that do not involve instrumentation. The results are observable and recorded as pass/fail, i.e. wheelchair lift platform functions as intended; lights function as intended, etc. Systems or components that fail shall be annotated with the corrective action taken and retested until passed.

The Successful Offeror shall, within 45 days after receipt of order, submit detailed plans for the performance of all ET tests. These plans, at a minimum, shall include all instruments to be used, their calibration certification, and the procedures to be followed.

Government acceptances of verification and designs shall constitute design freezes and enable the Successful Offeror to proceed with production activities relative to the accepted designs. The design freeze shall be effective for the duration of the production of the entire quantity of vehicles being procured.

Verification Matrix

SECTION NO.

REQUIREMENT TO BE

VERIFIED

TYPE OF

VERIFICATIO

N

WHEN

REQUIRED

3.0 Requirements Curb weight estimate of

completed vehicle and compliance to payload capability requirement.

COC PDR

3.0 Requirements Completed vehicle weighed for

compliance to payload capability requirement.

ET FVI and all subsequent units

3.1 Chassis Chassis option codes ordered to

prove compliance

COC

PAC

3.2.1 Body Mounting Mounting, framing, exterior COC PDR/FVI

3.2.2 Body Construction

and Undercoating

Design and Installation COC PDR/FVI

3.3 Body Upfitting Design, Layout and Installation COC PDR/FVI

3.7 – 3.8 Electrical Wiring diagrams COC PDR/FVI

4.1 Generator Load

Test

Full load capability and load management system performance

ET CDR and all subsequent units

4.2 Pre-Service

Inspection

TMC RP 803 Inspection COC FVI and all subsequent units

4.3 Road Test TMC RP 803 Inspection ET FVI and all

subsequent units

4.4 Vocational Test All equipment functionality ET FVI and all subsequent units

4.5 Vehicle Inspection Inspection COC FVI

6.0 Drawings and

Weight Estimations

All required body features, basic body structure, body/cab interface details, layout including tanks, dispensing sub-systems, lights, etc.

Layout drawings, estimated weight distribution

CO

C

CDR

4.0 TESTING, INSPECTION/ACCEPTANCE, AND TRAINING

4.1 AC Generator Load Test

The 6KW AC generator shall be tested for two hours at full load rating. A resistive load bank shall be connected directly to the generator output. The chassis engine, PTO, hydraulics, and generator shall operate without interruption or malfunction for the duration of the test.