Attachment G Wreckers 2010FederalPurchaseDescript.7.14.09Corrected.doc

FFAH-BB-030700-N

AMENDMENT NO.

Rev. December 8, 2003

PAGE

ATTACHMENT G

WRECKERS

1 July 2009

FEDERAL PURCHASE DESCRIPTION

LIGHT, MEDIUM, AND HEAVY WRECKERS

WITH HYDRAULIC UNDERLIFT AND RECOVERY BOOM

1 SCOPE AND CLASSIFICATION

1.1 Scope.

This specification defines five standard wreckers equipped with hydraulic underlifts and recovery booms of varying capabilities .

1.2 Classification.

· Trucks - light, medium, and heavy wreckers with hydraulic underlift and boom.

2 APPLICABLE DOCUMENTS

The following sections provide lists of documents specifically mentioned within the body of this purchase description. This list is not necessarily inclusive of all standards requiring adherence as cross-references may apply.

2.1 Government Publications.

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

· Federal Standard Number 307, 794, and 807

· GSA Acquisition Manual (GSAM).

The Code of Federal Regulations (CFR) and the Federal Register (FR) are for sale on a subscription basis from the Superintendent of Documents, U.S. Government Printing Office, Washington DC 20402. They may also be accessed on-line at www.access.gpo.gov. GSAM can be accessed on-line at www.arnet.gov/GSAM/ gsam.html.

Single copies of these specifications and other federal specifications and commercial item descriptions required by activities outside the Federal Government for offering purposes are available without charge from the General Services Administration, Federal Supply Service, Specification Section, Suite 8100, 470 L’Enfant Plaza, SW, Washington DC, 20407.

Within the body of this text, reference to the individual Federal Vehicle Standard Numbers shall be noted by ‘FSN’.

2.2 Other Publications.

The following documents form a part of this specification to the extent specified herein. Unless a specific issue is identified, the issue in effect on the date of invitation for offers or request for proposal shall apply.

2.2.1 Society of Automotive Engineers, Inc. (SAE).

Applications for copies of SAE publications should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale, PA 15096. Standards can also be obtained from their on-line store at www.sae.org.

2.2.2 Other Standards.

· The Tire and Rim Association, Inc. Year Book

· ASME/ANSI B18.18.1M-1987 – Inspection and Quality Assurance for General Purpose Fasteners

· TMC RP 803 – Pre-Service Vehicle Inspection (Published by The Technical and Maintenance Council of the American Trucking Association, 2200 Mill Road, Alexandria, VA 22314).

The Tire and Rim Association Year Book can be ordered on-line at www.us-tra.org/ publications.html. CEMA standards can be obtained at www.cemanet.org/publications/ index.html. ASME codes can be purchased at http://www.asme.org/codes/. Form TMC RP 803 can be obtained by contacting The Technical and Maintenance Council of the American Trucking Association, 2200 Mill Road, Alexandria, VA 22314.

2.3 Order of Precedence.

In the event of a conflict between the text of this purchase description and the references cited above, this purchase description takes precedence. Nothing in this purchase description, however, supercedes applicable state and federal safety laws and regulations and the requirements set forth in the vehicle manufacturer’s Body Builders Layout Book and Incomplete Vehicle Manual.

REQUIREMENTS

2.4 General

The wreckers shall be equipped for both towing and recovery. Item 971 shall be used primarily for towing operations. Items 972 through 975 shall be used for both tow and roll functions. A schematic of the wreckers is provided in Figure 1.

(Wrecker picture below to be utilized for references for Items 971- 974.)

Figure 1: Graphical representation of key wrecker measurements referenced within the body of the federal specification (tandem rear axle shown).

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

Modifications to the chassis shall be Government approved and conform to all of the requirements set forth in chassis manufacturer’s Body Builders Layout Book and Incomplete Vehicle Manual applicable to the specific chassis model and year of manufacture.

When a component or equipment “Rating” is requested, the furnished information shall be the manufacturer’s published maximum for that piece of equipment, independent of any other wrecker component. When component or equipment “Capacity” or “Capability” is requested the furnished information shall be as installed on a completed wrecker as specified herein, with out options. Component or equipment “Capacity” or “Capability” may possibly be limited by other lesser-rated wrecker component or equipment. The “Capacity” or “Capability” stated shall also meet the axle loading requirements of SAE J2512 sections 5.9.1, 5.9.2 (with a 0.50 “K” factor), and 5.9.3 as applicable.

2.5 Chassis and Cab.

The chassis model and options furnished shall be the chassis manufacturer’s current version or newer on the date of order. The base cab and chassis are defined for each standard item number in the comments section of the applicable standard item.. The chassis shall comply (at a minimum) with all requirements of the referenced Standard Item Number, except where modified herein. The referenced Federal Standard shall be the version in effect on date of order.

2.5.1 Chassis.

2.5.1.1 Frame.

The required CA shall be based on the cab and wrecker body length requirements. A minimum 2” (maximum 4”) gap between the wrecker body and the rear of the cab or rear most components shall exist.

For each standard item, the frame must resist, without failure, the respective loads with hydraulic jacks down, if applicable. The minimum frame rail RBM rating shall be that listed. Frame reinforcement shall extend beyond the rear axles to the end of the frame. Any localized frame reinforcement shall have tapering of less than 30deg. for improved stress distribution.

See Section 6.2 for definitions of the requested offering information below.

2.5.1.2 Axles.

Axles shall not be overloaded relative to their GAWR ratings under either un-laden or laden conditions. Front axle shall have a minimum GAWR equal to that list listed in the item description. Rear axles shall be single reduction drive axle(s) having a minimum GAWR equal to that listed.

For Item 975, a setback front axle shall be furnished according to FSN 3.4.9.

For Items 973 through 975, the hubs on the steer axle shall be oil lubricated and have a window for visual monitoring of the oil level. Synthetic lube shall be furnished. Provisions for venting or withstanding internal pressure buildup and for replenishing the oil supply shall be provided.

For Items 971 and 972, the chassis OEM rear limited-slip differential shall be supplied. For Items 973 through 975, the rear differential ratio shall be selected according to the following speed requirements:

· Maximum speed – the wrecker shall be capable of, and limited to, a maximum sustained speed between 70mph and 75mph, at its GVWR, 0% grade, at or below rated engine speed, in the final available transmission gear. Electronic road speed governing shall be an acceptable method of limiting maximum speed.

Calculations for gradeability and maximum geared speed shall be based on SAE J2188 standards. Wind and altitude can be neglected.

For Items 973 through 975, if Option D1 is specified, a driver controlled differential lock (DCDL) shall be provided in all rear axles. All DCDLs shall automatically disengage at the maximum vehicle road speed recommended by the differential manufacturer.

For all Items, if Option ATC is specified, ABS automatic rear traction control shall be furnished. If Option ATC is furnished, the limited-slip differential requirement for Items 971 and 972 shall be deleted.

For Items 971 and 972, if Option AWD is specified, the manufacturer’s standard four-wheel drive package will be installed. The transfer case shall be a minimum of two speeds.

A permanent magnet type drain plug shall be installed in all differentials (see FSN 3.1.1.4).

For Items 973 through 975, if Option LSD is specified, the rear differentials shall be delivered with the recommended fill capacity of synthetic lubricant that meets the manufacturer’s requirements.

2.5.1.3 Suspension.

Basic requirements are set forth in FSN 3.4.8.

For Items 971 and 972, the front and rear suspension shall be the highest rated multi-leaf spring suspension available from the chassis supplier. The OEM’s torsion bar and shock absorbers shall be furnished for both axles.

For Items 973 through 975, the front suspension shall be the chassis manufacturer’s multi-leaf spring suspension with shock absorbers rated. For single and tandem rear axle vehicles, a multi-leaf spring suspension shall be furnished. Auxiliary rear springs shall also be furnished.

If Option SAR is selected for items 974 and 975, an air suspension shall be supplied for the rear axle(s). Requirements are set forth in FSN 3.4.8.1.

2.5.1.4 Brakes.

Brakes shall be the largest size, highest capacity available for the truck model and axle capacity offered.

For Items 971 and 972, the heaviest OEM offered hydraulically controlled disc brakes shall be furnished. A four wheel antilock braking system shall also be installed.

For Items 973 through 975, air actuated, drum or disc brakes with automatic slack adjusters shall be furnished.

2.5.1.5 Wheels.

Hub-piloted disc wheels for tubeless tires shall be provided on the front, spare, and rear tire assemblies. Except for Item 975, rear, front, and spare wheel size shall be identical as shown. All wheels shall adhere to SAE J694 standards for hub/wheel interface dimensions and The Tire and Rim Association, Inc. Year Book rim requirements. Maximum load rating for the rim shall not be less than the permissible loading of the furnished tire. When “WLP” is specified, wheels shall be painted the same color as cab.

2.5.1.6 Tires.

Tires shall be OEM supplied, tubeless, and rated for all-season use. Total tire load capacity, at recommended inflation pressures, shall be at a minimum equal to the GAWR of the associated axle. Tires shall be rated for a minimum of 75 MPH at the design capacity and pressure. For all Items except 975, drive, steer, and spare tires shall be identical as shown.

For Items 973 through 975, if Option STA is specified, a chassis OEM supplied spare tire assembly (tire and wheel) exactly matching the front tire and wheel shall be furnished.

If Option CTIS is specified, a central tire inflation system shall be furnished (see FSN 3.1.1.20 for requirements).

2.5.1.7 Engine.

The vehicle and engine shall conform to 40 CFR Subchapter C-Part 86 - “Control of Emissions from New and In-use Highway Vehicles and Engines", as evidenced by an EPA certificate of compliance. Vehicles shall also comply with all pollution control requirements for the state of final destination. Certificates of compliance shall be made available upon request.

For all Items, an electronically controlled, turbocharged, diesel engine producing the minimum gross brake power and gross brake peak torque ratings shall be supplied.

The provided engine calibration shall have low-idle and high-idle settings equal to that required by the combination PTO/hydraulic pump set point.

For Items 973 through 975, an engine automatic shutdown system shall be furnished. The shutdown system shall include low oil pressure, low coolant level, and high coolant temperature audio and visual alarms, with 30 seconds warning, as well as a manual override. (see FSN 3.4.19).

Emissions certification for the ultimate vehicle destination is required.

2.5.1.8 Engine Coolant Heater.

If Option SEHA is specified, a 120VAC, immersion style, thermostatically controlled, block coolant heater with power cord shall be furnished. The heater shall be rated according to the engine’s total displaced cylinder volume and shall supply a minimum of 115W/L. The heater shall be threaded or plate style. The heater shall be approved for use in the supplied engine and shall be installed per the manufacturer’s requirements. The deactivation temperature shall be 120degF. The heater cord shall be a minimum of 25ft in length and shall be of sufficient wire gauge to safely conduct the required current.

The heater shall be wired to an externally accessible slave receptacle located below the driver’s side door. The receptacle shall have a weatherproof, hinged cover that remains securely closed during vehicle operation. The wiring shall have circuit breaker overload protection.

2.5.1.9 Engine Starter and Starting Aid.

A 12VDC starter with thermal over-crank protection shall be furnished. The starter shall only be operational if the transmission is in neutral or park (interlock).

For Items 973 through 975, remote jump-start post(s) shall be mounted in an easily accessible location.

For Items 971 and 972, OEM supplied glow plugs shall be furnished to automatically assist in cold-start conditions. For Items 973 through 975, either an electric grid heater or ether starting system shall be furnished (see FSN 3.4.2.1 for requirements). The starting aid system shall be key operated (automatic) and shall only be operable within the appropriate temperature range specified by the engine manufacturer.

2.5.1.10 Exhaust Intake/Plumbing.

The intake shall have as a minimum a single-stage air filter assembly capable of handling peak airflow requirements and shall be mounted within the engine compartment. Stainless steel, constant-torque hose clamps shall be used with all intake system connections. When option ASI is specified, the air filter shall have a dash mounted, illuminated, resettable Filter Minder® installed per the manufacturer’s recommendations.

For Items 971 through 974, the exhaust system shall be the chassis manufacturer’s standard horizontal stainless or aluminized steel.

For Item 975, the exhaust pipe(s) shall be mounted vertically behind the cab. Chromed, aluminized, or polished stainless steel heat shields shall be provided. Either a chromed, aluminized, or stainless steel hinged rain cap shall be provided for pipes with vertical openings or the stack pipes shall be bent rearward so that the opening cross-section parallels the vertical rise. Stack pipes shall not extend more than 12” above the cab nor beyond 13’5” from the ground. CT computations will be considered when meeting this requirement.

2.5.1.11 Batteries.

The furnished batteries shall be 12V, high-cycle, and maintenance-free. For Items 971 and 972, the chassis OEM dual battery system shall be furnished.

For Items 973 and 974, a minimum of three batteries shall be furnished. For Item 975, a minimum of four batteries shall be furnished. For Items 973 through 975, each battery shall have a minimum cold cranking amperage of 625A and a minimum reserve capacity of 180 minutes.

2.5.1.12 Compressed Air Supply.

For Items 973 and 974, the engine driven air compressor shall have a minimum flow rating of 13scfm. For Item 975, the engine driven, governed air compressor shall have a minimum flow rating of 16scfm.

2.5.1.13 Air Dryer.

For Items 973 through 975, a 12VDC air dryer for the compressed air shall be provided, Bendix AD-IP with integral purge or equal (see FSN 3.4.11.1.1). Installation shall be immediately downstream of the engine air compressor and in accordance with the manufacturer’s recommendations and SAE J2383.

2.5.1.14 Cooling System.

A 50% ethylene glycol / water solution shall be used in determining requirements. The antifreeze/coolant solution shall comply with TMC-RP329. Extended Life Coolant (ELC) shall be used if allowed by chassis and engine manufacturers. An automatic fan clutch shall be supplied (see FSN 3.4.1.6). When available from Chassis OEM, all radiator and heater hoses shall be constructed of a premium grade EPDM rubber compound.

Stainless steel, constant-torque hose clamps shall be used with all cooling system connections. A bug/rock screen shall be provided and the radiator shall have a lower drain valve.

A coolant recovery bottle with sufficient volume to meet the expansion, deaeration, and drawdown requirements of the entire system shall be supplied. The bottle shall be placed as high and close to the pressure cap as possible.

2.5.1.15 Fuel Tanks.

For Items 973 through 975, if Option FTC is specified, the fuel tank(s) shall have a minimum total capacity of 70 gal. If Option FTD is specified, the fuel tank(s) shall have a minimum total capacity of 100gal.

If more than one tank is provided, the tanks shall be plumbed for tank-to-tank fuel level equalization without requiring operator intervention.

For Items 973 through 975, steel tanks shall be primed or aluminized and have a black finish coat. Each tank shall be secured under the cab with primed, black finish-coated steel bands. Rubber isolators shall be used between the tanks and the bands. Tanks for Items 973 through 975 shall be located as far forward along the side of each frame rail as possible. Fuel tanks shall adhere to 49 CFR 393.65/67 requirements.

If Option SEHD is specified, an in-tank fuel warmer shall be furnished. The warmer shall use engine coolant to transfer heat to the fuel and shall be thermostatically controlled. Fuel warmers shall meet SAE J1422 requirements and shall be installed according to the manufacturer’s recommendations.

2.5.1.16 Fuel Transfer.

The engine mounted fuel filter shall be capable of handling the maximum flow rate produced by the fuel pump and shall have a final filtration rating equal to that specified by the engine manufacturer. Items 973 through 975 shall have a heated fuel/water separator furnished. It shall be capable of handling the maximum flow rate produced by the offered fuel pump and have a metal container for water with a manual drain valve. The separator shall notify the operator when the bowl needs to be emptied. See FSN 3.4.1.9(C ) for heater performance requirements. The heater shall be thermostatically controlled.

2.5.1.17 Clutch.

For Items 973 and 974 with manual transmissions, an Eaton Fuller Solo Medium-Duty, Maintenance-Free, 14” diameter, two-plate clutch rated at a minimum of 860lb-ft, or equal, shall be furnished. For Item 975 with manual transmission, an Eaton Fuller Solo Heavy-Duty, Adjustment-Free, 15.5” diameter, two-plate clutch rated at a minimum of 1,450lb-ft, or equal, shall be furnished.

2.5.1.18 Transmission.

The transmission’s input torque rating shall be equal to or exceed the engine’s peak torque and shall also be capable of transmitting the PTO torque required for the operation of the hydraulic pump. The transmission shall be rated for the supplied chassis GVWR and be rated at a minimum for the engine’s peak power output. A magnetic drain plug shall be provided (see FSN 3.1.1.4).

For Items 971 and 972, the chassis manufacturer’s largest available transmission oil heat exchanger shall be furnished.

For Item 975, the manual transmission shall include a water/oil heat exchanger and an integrated oil pump.

If Option T6A is specified for Items 973 through 975, a minimum of a six speed automatic transmission with an external oil cooler shall be furnished.

If Option LST is specified, the transmission shall be delivered with the recommended fill capacity of synthetic oil that meets the manufacturer’s requirements.

2.5.1.19 Front Bumper

A channel type, full-width, front bumper shall be furnished.

The front bumper shall be steel with a corrosion-resistant primer and shall have a gray or black finish coat, or chrome finish on all surfaces.

If Option FPB is specified, a front push bumper shall be furnished. The push bumper shall be full width, with a minimum top to bottom dimension of 14 inches. Bumper shall have a full width black, non-mar rubberized covering and be attached to the vehicle chassis frame rails in the same manner as the chassis OEM bumper. Push bumper shall be installed in compliance with all requirements in the chassis OEM body builders book, and shall allow airflow in critical cooling or intake areas as designated in the body builder’s book. Push bumpers shall not interfere with or defeat deployment of SRS air bag.

2.5.1.20 Automatic Tire Chains.

When Option AICE is specified, Onspot, or equal, automatic tire chains shall be provided for use with rear tires.

The compressed air required for operating the actuation solenoids shall be sourced from the engine compressor. If an engine compressor does not exist, a 12V air compressor and holding tank shall be furnished. An electric actuation switch with an indicator lamp shall be placed in the cab.

2.5.2 Cab.

2.5.2.1 Cab Design.

The cab shall be of conventional design with two doors (see FSN 3.4.12 for requirement details). For Items 971 through 974, if Option CC is specified, the OEM’s four-door crew cab shall be furnished.

Exterior driver/passenger side breakaway side mirrors shall contain both flat and convex areas (see FSN 3.4.20). Exterior side mirrors shall be mounted to allow viewing in accordance with FMVSS 111. For Items 971 through 974, the exterior of the mirrors shall either be encased in a black composite material or have a black finish coat. For Item 975, the exterior of the mirrors shall be either polished or chromed.

If Option RM4 is specified, dual heated side mirrors shall be provided. If Option RM3 is specified, dual heated side mirrors shall be provided and the passenger side mirror shall be motorized.

The grille shall be chrome or match the appearance of the front bumper or cab.

The windshield shall have tinted glass. A rear cab window shall be furnished. For Items 971 and 972, if Option SRG is specified, the rear window shall have a sliding glass feature.

For Items 971 and 972, if Option RB is specified, running boards shall be supplied on both driver and passenger sides. Each board shall span, at a minimum, the length of all doors and shall be securely attached to the frame. Each board shall be capable of supporting a minimum concentrated load of 300lbf at a location centered on the door (a two-point simultaneous load application applies for Option CC). The boards shall either be an integrated, molded black platform or a black finish coated tubular bar with a step insert.

For Items 973 through 975, cab entry steps shall be provided on both driver and passenger sides for each door. Each step shall be capable of supporting a minimum load of 300lbf. The steps can be integrated into the battery box or fuel tank(s) in which case they shall be of identical material and finish.

Front, frame-mounted tow hooks, accessible through the front bumper, shall be furnished.

3.2.2.2 Cab Switches and Gauges.

The cab switches and gauges shall include, but are not limited to, the following:

· Speedometer (with odometer/trip)

· Tachometer

· Engine oil pressure gauge

· Coolant temperature gauge

· Voltmeter (Items 973 through 975)

· Fuel level gauge (1 gauge per tank or tank selector switch)

· Engine hour meter (Option EHM)

· Air suspension pressure (Items 973 through 975)

· Air cleaner restriction service gauge (Option ASI)

· Automatic tire chains indicator lamp and switch (Option AICE)

· Tire inflation pressure gauge and switches (Option CTIS)

· Engine ‘protect’ (problem) lamp

· In-tank fuel warmer indicator lamp (passive, Option SEHD)

· Water separator drain indicator lamp (passive, Option EBO)

· Water separator heater indicator lamp (passive)

· Mirror control switch (Option RM3)

· Mirror heater indicator lamp and switch (Option RM3/RM4)

· Glow plug lamp (passive, Items 971 and 972)

· Compression brake override switch (Option ECB)

· PTO engagement switch and indicator lamp

· DCDL switch and indicator lamp (Option D1)

· IAD lock switch and indicator lamp (Item 975)

· All-wheel drive engagement mechanism and lamp (Option AWD)

· Emergency light bar switch and lamp

· Emergency light bar work lights switch and lamp

· Floodlight (underlift) switch and lamp

· Floodlight (pylon) switch and lamp

· Spot light (recovery) switch and lamp (Items 974 and 975)

· Parking brake switch and lamp

· Full underlift controls

· Trailer (towed vehicle) air brake release/control switch and 7-pin lighting receptacle switch and lamp (Items 973 through 975), and

· Towing lights 4-pin receptacle switch and lamp (as required).

Warning lamp(s) and buzzer(s) shall also be supplied to identify at a minimum: high engine coolant temperature, low oil pressure, low coolant level (see FSN 3.4.19), low battery voltage (<12.5V), and low brake air pressure (<60psig) (see FSN 3.4.11.1).

All switches shall be placed within reach of the seated driver.

2.6 Wrecker Performance Requirements.

2.6.1 Recovery Boom.

For Items 972 through 975, the boom shall be a minimum of a dual stage hydraulic assembly. Nylatron®, or equal, slide pads shall be used. The boom shall be capable of supporting the minimum vertical static load (not including the integrated underlift if present).

Item 971 shall have a single stage (fixed) boom with an attached integrated underlift. The boom shall be capable of supporting the maximum lift and tow working load allowed by the underlift without failure. If Option WEB is specified, Item 971 shall be furnished with a two stage hydraulic boom as defined above for Items 972 through 975.

For all Items, the boom’s pivot assembly and rated structural capability shall include, in regards to static loading, a minimum factor of safety of 1.5 for all possible extensions and elevations. The boom shall be capable of elevating from fully lowered to fully raised within 10 seconds. The boom shall be capable of extending from its fully retracted position to fully deployed within 30 seconds. Simultaneous operation of the boom elevation cylinders, stage extension cylinders, and winches at their top speed shall not affect full travel time requirements.

For Items having an extendable recovery boom, wire rope sheave ends shall be provided which permit 360-degree rotation of the guide pulley. Sheave pitch to wire rope diameter ratio shall be a minimum of 8 to 1 per SAE J2512. For Item 971 without Option WEB, vertical roller wire rope guides shall be provided at the end of the recovery boom.

For Items having an extendable recovery boom, a means of allowing the operator to identify boom elevation and extension shall be provided. If electronic position feedback is not incorporated, the retractable stages of the boom shall be marked in 6” intervals with numbering every 12”. A boom angle gauge with graduations visible from the rear of the wrecker shall also be furnished. If an overload protection system is not provided, lookup tables shall be furnished stating allowable boom loading as a function of elevation and extension.

2.6.2 Winch and Wire Rope.

The furnished recovery winches shall conform to SAE J706 and shall be hydraulically driven. Winch operating speed shall be dependent upon travel of control levers and shall be continuously variable.

Each winch shall have a minimum first layer line pull rating as shown below. (see Table XV).

Table XV: Required minimum winch rating.

(lb)*

The winches shall contain planetary gears and shall be controllable in either direction, and shall be mounted at the pivot end of the recovery boom as far from the wire rope sheaves (underlift end) as possible. For Std Items 971-973 worm gear winches controllable in either direction may be substituted. The mounted winches shall each be capable of withstanding twice the maximum rated line pull per SAE J706 without damage.

Wire rope shall be supplied with each winch. The minimum wire rope construction shall consist of 6 strand x 37 wire, regular lay, Extra Improved Plow Steel Grade or greater strength (XIPS, EIPS, or greater), Independent Wire Rope Core (IWRC). Each wire rope shall have a minimum working strength and nominal breaking strength as listed in Table XVI.

Table XVI: Required minimum wire rope working and break strength ratings.

(lb) Minimum Wire Rope Nominal Breaking Strength Rating

(lb)

The required minimum length and diameter wire rope is noted in Table XVII.

Table XVII: Required wire rope length and diameter.

Length

(ft) Min. Diameter

(in)

The winch drum shall be capable of storing, in layers, the entire wire rope less that required to span the retracted boom. The two winch lines shall be run parallel to one another along the recovery boom, through the sheaves, then terminate with crimped safety hooks. All connections and hardware shall have a minimum breaking strength rating equal to that of the rope. A Flemish eye splice shall be used for connecting the safety hooks. Safety hooks shall be prevented from moving when stowed.

The winches shall contain a drum release clutch. For Items 971 thru 973, the drum release clutch shall be manually activated. For Items 974 and 975, the drum release clutch shall be air-actuated. Drum re-engagement shall be automatic upon disengagement of the free-spool control. The winches shall have a drum drag brake to maintain wire tension at the drum during free-spooling (line feeding) and a rope leveler to keep wire rope winding uniform and under tension. The winches shall have an automatically adjusting safety brake system capable of holding the maximum rated line pull per SAE J706 if hydraulic pressure is lost.

The winch manufacturer’s identification plate shall be affixed to each winch. Winch capability as a function of rope payout (layers) for the supplied rope shall be provided with the vehicle in the operator’s manual.

2.6.3 Underlift.

The underlift assembly shall be secured to the vehicle chassis or boom. The securing hardware shall be capable of withstanding 150% of the maximum allowed bending moment. The underlift assembly shall also meet all strength requirements set for by 49 CFR 393.71.h.

For Item 971, the hydraulic underlift shall be of the self-loading type. This shall include an integrated wheel lift on the rotatable crossbar that hydraulically secures the tires. The underlift shall be capable of securing a vehicle for tow when approached at 90deg.

For Items 972 and 973, the hydraulic underlift shall include integrated wheel chocks on the crossbar with manually adjustable wheel (‘L’) brackets.

For Items 974 and 975, the hydraulic underlift shall consist of a minimum of two stages and contain a rotatable crossbar. Adjustable Nylatron®, or equal, slide pads shall be used. When not in use, the crossbar shall not be allowed to rotate and the underlift shall be capable of being stowed with the boom vertical relative to the ground. Adequate clearance shall exist between the stowed underlift and stowed recovery boom to prevent rubbing and shall not interfere with the operation of the boom.

The underlift shall be capable of lifting the minimum working load at the listed SAE J2512 lift point (LP). The structural capacity of the underlift assembly shall have a minimum safety factor of 1.3 in regards to the static working load according to 49 CFR 393.71.h.1 requirements. Lifting of the stated load shall be possible without overloading the rear axle(s) or under loading the front axle (defined by SAE J2512, Section 5.9, as having less than 50% of the front axle static loading) with full fuel, and all supplied accessories. Ballast may be secured behind or integrated into the front bumper or wrecker body/subframe/chassis to meet laden front axle load requirements.

For Items 974 and 975, the underlift shall tilt from its fully lowered position to fully stowed within 20 seconds. Simultaneous operation of the underlift tilt and stage extension cylinders shall not affect full travel time requirements. For all Items, the underlift shall be capable of extending from its fully retracted position to fully deployed within 20 seconds.

The underlift shall be capable of lifting all working loads from ground level to a minimum height of 10”. Vertical adjustment of the underlift shall be possible during other underlift operations. The underlift shall have tilt up / tilt down capabilities of a minimum ±8deg relative to the horizontal.

A means of allowing the operator to identify underlift boom extension and tilt shall be provided. If electronic position feedback is not incorporated, the retractable stages of the boom shall be marked in 6” intervals with numbering every 12”. If an overload protection system is not provided, a lookup table shall be furnished stating allowable underlift loading as a function of extension.

A safety device shall be provided to lock the underlift position while either stowed or in use.

2.6.4 Towing Capability.

The towing load capability of the underlift and wrecker shall permit towing of the minimum load listed in the min requirements listing. The towing capability is defined as the maximum un-braked vehicle weight that can be towed without exceeding the wrecker chassis GVWR (for un-braked tow loads, GCWR=GVWR).The maximum allowed towed load limits without operational brakes on the towed vehicle shall be furnished in the supplied operating manuals.

2.6.5 Hydraulic Lifts (Jacks).

For Items 974 and 975, two hydraulically actuated lifts shall be provided and positioned at the outside-rear of the wrecker. These lifts shall be capable of unloading (supporting) the rear bogie with a combined (gross) load capacity of 150% of the maximum allowable recovery boom load. Each lift shall have a flat foot and a spade attachment rated for a minimum normal load equal to the vehicle’s GVWR. The lifts shall be operable either independently or together. Each lift, whether operated independently or together, shall be capable of translating through its full range of travel within 10 seconds.

2.7 Wrecker Body and Associated/Auxiliary Hardware.

2.7.1 Wrecker Body.

The wrecker body shall be of either aluminum or composite construction. The chassis frame rails shall be the load bearing members during use of the recovery boom, underlift, or jacks (as applicable). The fasteners used to secure the body and subframe to the chassis frame shall be of constant torque (locking) type. U-bolts are not acceptable. The securing hardware shall be capable of withstanding 150% of the maximum anticipated load. The method used to attach the subframe to the chassis shall comply with the chassis manufacturer’s Body Builder Instructions for chassis supplied.

The body shall contain storage compartments for all supplied auxiliary equipment and room for operator accessories. All available area on both sides of and underneath the wrecker shall be utilized for storage. The tool compartments shall be isolated from the frame using elastomeric mounts. For all Items, a method of storing and securing the safety chains near the tailboard of the wrecker shall be furnished. The means used for securing each safety chain to the wrecker shall withstand a load in any direction greater than the breaking strength of the supplied chain.

For Items 972 and 973, a means of securing tow bar mounting brackets to the rear of the wrecker body shall be furnished. The mounting device shall be able to withstand a minimum of 150% of the rated working loads for the offered tow sling assembly without failure.

For Items 971 through 973, the wrecker body deck floor shall be polished aluminum diamond plate or equivalent.

For Items 972 through 975, a tunnel compartment shall be provided in the front part of the wrecker body. This compartment shall extend the full width of the wrecker body and be accessible from either side.

All wrecker body compartments shall be lighted, weatherproof, and have integrated stainless steel locks, stainless steel hinges, stainless steel latches, and drains. A driver’s controlled in cab light switch will be provided. Positive retention systems shall be incorporated into the storage compartments for all supplied lift and tow accessories. The interior of the tool compartments shall have an abrasion-resistant finish. All wrecker body locks shall be keyed identically. Two sets of keys shall be provided.

For Items 973 through 975, a trailer brake control system shall be installed according to FSN 3.1.1.8 and FSN 3.4.11.2. The pintle hook shall be furnished as an underlift accessory. Gladhands, air connection, and the 7-pin lighting receptacle shall be located at the rear of the wrecker and shall be protected from inadvertent contact. A weatherproof, hinged or tethered, corrosion resistant cap shall cover the lighting receptacle.

For all Items, a 4-pin receptacle for use with auxiliary tow lights (see Section 3.3.6) shall be installed at the rear of the wrecker. A weatherproof, hinged or tethered, corrosion resistant cap shall cover the lighting receptacle. For Items 973 through 975, a 7-pin/4-pin adaptor can be furnished in lieu of a receptacle.

Wheel wells shall allow full suspension travel without the possibility of tire contact while having snow chains attached (in accordance with SAE J683).

Rubber mud flaps shall be supplied behind the rear-most axle. The mud flaps shall adhere to SAE J682 standards for rear wheel splash and stone throw protection. See FSN 3.1.1.7 for additional requirements.

2.7.2 Control Stations.

Driver and passenger side wrecker controls shall be provided at the rear of the wrecker body. For Item 971 Driver controls may be provided in cab. For Item975, these stations shall be enclosed in compartments as defined in Section 3.4.1. Each station shall allow control of those items used during a recovery effort including, but not limited to, the following labeled items:

· Hydraulic lifts (if furnished)

· Recovery boom (if adjustable)

· Winches (speed control, free-spool, forward/reverse)

· Underlift

· Hydraulic oil pressure (regulator, if necessary), and

· Flood and spot lights, including the work lights on the lightbar.

Control handle stroke shall be adjustable.

The following minimum gauges shall also be located and labeled within the control station.

· Recovery boom/underlift position and load electronic feedback (if supplied), and

· Hydraulic oil pressure gauge.

Vibration-damped, weatherproof, corrosion-resistant, gauges shall be provided. The gauges shall either be liquid-filled with silicone oil or Fluorolube® or be connected to snubbers to filter pressure pulsations. All gauges shall be labeled to identify the pressure source. Gauge graduations shall provide resolution within 10% of full-scale deflection under normal loads. Gauge units shall be English (psig). The ambient temperature operating requirements for the instruments shall be –40degF to +125degF. All gauge taps shall be selected to reflect local stagnation pressures.

For Items 974 and 975, a wireless remote control capable of operating the winches, recovery boom, and underlift at a minimum distance of 200ft. from the rear of the wrecker shall be provided. For Items 971 through 973, a tethered or wireless remote control capable of operating the underlift at a minimum distance of 10ft. from the rear of the wrecker shall be furnished. Wreckers using wireless remote controls will have cab or chassis mounted controls also.

2.7.3 Vehicle Identification Plate.

A metallic identification plate shall be permanently affixed within each control station in a prominent location reflecting the following information:

1. Wrecker manufacturer’s model

2. Wrecker assembly serial number

3. Front and rear GAWR

4. GVWR

5. Maximum working lift/tow capacity (with inoperable brakes on towed vehicle)

6. Winch line pull rating for full drum

7. Winch line pull rating for last layer (based on furnished cable)

8. Wire rope diameter

9. Wire rope length

10. Wire rope working strength

11. Wire rope breaking strength

12. Maximum underlift working tow capacity.

2.7.4 Light Pylon and Emergency/Auxiliary Lighting.

A light pylon shall be installed at the front of the wrecker body. An emergency lightbar with amber lenses and rear-facing work/tail/brake lights shall be installed upon the top of and centered on the pylon. The pylon height shall be sufficient to allow unobstructed forward transmission of light from the emergency lightbar. The lightbar LED and work lights shall be activated by separate switches in the cab. A double-flash pattern with a firing frequency of 60 to 120 FPM shall be utilized for each strobe.

For Items 971 through 974, a 58” Whelen Towman’s 9M Model 9M240W00 having four LED , or equal, shall be provided. The lightbar flash synchronization shall be programmed as shown in Figure 2 (matching numbers indicate simultaneous flashing).

Figure 2: Lightbar flash synchronization for Items 971 through 974.

For Item 975, a Whelen, 72” Whelen Towman’s 9M Model 9M280W00-9MLTH1 having eight LED , or equal, shall be provided. The lightbar flash synchronization shall be programmed as shown in Figure 3 (matching numbers indicate simultaneous flashing).

Figure 3: Lightbar flash synchronization for Item 975.

Pivotable floodlights shall be placed near the right and left top underside corner of the light pylon to assist in illuminating the wrecker body deck / recovery boom. Floodlights shall be a minimum of a 3”x4” trapezoidal flood, 5,000 candlepower. A second set of pivotable floodlights shall be provided for underlift illumination. The floodlights shall be located on the right and left side of the tailboard at a height lower than the top of the wheel well. Floodlights shall be a minimum of a 4” trapezoidal flood, 3,000 candlepower.

For Items 974 and 975, swivel base spot lights shall be supplied on the right and left upper rear side of the wrecker body facing rearward to assist in recovery lighting. Spot lights shall be a minimum of 4 3/4”, 100,000 candlepower.

All lights shall be weatherproof, encased in black rubber, serviceable, and corrosion resistant. Each set of lights shall be operated from separate switches located in both rear control panels.

2.7.5 Hydraulic System.

2.7.5.1 Hydraulic Pump(s).

The hydraulic pump rated flow shall satisfy all required hydraulic cylinder performance requirements. The pump shall be capable of operation in ambient temperatures ranging from –30degF to +120degF.

2.7.5.2 PTO.

The PTO shall be transmission mounted, electrically activated, and designed to handle a minimum of 1.5 times the peak anticipated torque. For vehicles equipped with an automatic transmission, the PTO shall be hydraulically engaged (electric over hydraulic). For vehicles equipped with a manual transmission, the PTO shall be air engaged (electric over air). The PTO shall be selected to allow the hydraulic pump to perform all required recovery / towing requirements at the engine’s high-idle speed. Activation of the PTO shall force the engine to the selected high-idle setting (minimum). Deactivation of the PTO shall return the engine to low-idle. Except for Item 971, the PTO shall not be permitted to engage or operate without the application of the parking pawl or, if parking pawl is not furnished, the parking brake. Release of the parking brake or parking pawl (as applicable) shall disengage the PTO. For Item 971, the PTO shall not be allowed to engage and shall automatically disengage at rotational speeds below the limiting maximum speed specified by the PTO or pump manufacturer (interlock).

The hydraulic pump shall be secured to the PTO. The transmission mounted pump/PTO assembly shall not exceed the load carrying capability of the transmission PTO bay or mating flanges. A factor of safety of 1.5 shall exist for all mounting surfaces and hardware when taking into consideration road shock. The PTO shall be installed with the backlash requirement specified by the manufacturer.

2.7.5.3 Hydraulic Cylinders.

The hydraulic cylinders shall be double-acting (powered in both directions) with chrome-plated rods. The cylinders shall be chosen and installed so as to be capable of supporting 150% of the allowable static working load at all positions.

An electro-hydraulic or mechanical control system shall be furnished for operation of all hydraulically driven components. Cylinder operating speed shall be dependent upon travel of control levers and shall be continuously variable.

2.7.5.4 Hydraulic Oil Reservoir.

The hydraulic oil reservoir capacity shall be a minimum of 1.5 times the capacity of the remainder of the system. The oil reservoir shall be baffled and shall have a vented and weatherproof cap. The oil return within the tank shall be below the dynamic oil level. A 300 mesh (50micron) strainer, at a minimum, shall be installed at the reservoir fill opening. A magnetic drain plug shall be provided. Means shall be provided to permit easy checking of oil level.

2.7.5.5 Hydraulic Oil Filters.

The hydraulic oil filter(s) shall provide, at a minimum, the recommended filtration rating specified by the hydraulic pump/motor manufacturer. If not specified, the minimum filtration shall be 10 microns. Flow capacity for the filters shall be a minimum of twice the hydraulic pump’s maximum flow rate. The filters shall be positioned so as to allow for unobstructed element replacement and shall be of spin-on type. The filter(s) shall be furnished with a pressure differential type service indicator or gauge.

2.7.5.6 Miscellaneous Hydraulic Components.

Holding valves shall be incorporated into the hydraulic system plumbing to prevent loss of hydraulic cylinder or winch loads or position if load retention is not an integral feature of the furnished components. Load retention shall occur automatically when winch/cylinder control handles are in the ‘neutral’ position, regardless of PTO engagement.

A high-pressure bypass valve shall be incorporated into the hydraulic system to protect the components from excessive pressure.

Unless hardware limits dictate a lower threshold, an oil cooler shall be provided if peak oil temperatures exceed 200degF during continuous pump operation. Hydraulic lines shall meet or exceed pump manufacturer’s minimum requirements for size and shall be stable at expected peak operating pressure and temperature. Stainless steel piping, which can assist in cooling, may be used if properly secured to the vehicle frame so as to prevent vibration induced fatigue failure. All lines shall be installed in accordance with the requirements and recommendations of the latest revision of SAE J1273. All hydraulic fittings shall be compatible with the furnished hydraulic lines and shall comply with requirements of SAE J516 for permanently attached (crimped) fittings. The system shall be designed for a factor of safety of three (3) relative to the pump pressure relief setting. The system pressure shall not exceed 3500psig.

If air entrainment is possible, provisions shall be made for bleeding air from the hydraulic system.

2.7.6 Towing Accessories.

Two safety chains with grab hooks on one end shall be provided, each rated in accordance with SAE J2512, Section 5.8 and 49 CFR 393.71.h.10 requirements. Minimum grab hook strength shall be equal to that of the chain. Safety chains shall be capable of properly securing a towed vehicle when a wheel lift is used and the underlift is fully extended (including allowing for adequate slack for turning).

Table XX: Required minimum safety chain Break strength rating requirements..

(lb / chain)* Minimum Length

(ft)

The minimum auxiliary equipment to be supplied shall include the following items:

· For all Items, retention (tie-down) chains for the underlift with end grab hooks on one end, bow shackles with clevis/cotter pin on the other, 6ft long (minimum), and rated, at a minimum, equal to the safety chains listed in Table XX (one set).

· For all Items, chain hook adapters for the underlift sized and rated for furnished chains (one set, either integrated into underlift or separate)

· For Items 971 through 973, nylon, ratchet type tire harnesses for securing tires to underlift with each rated, at a minimum, equal to 1/2 of the maximum offered underlift rating (one set)

· Snatch blocks (one for Item 971, one set for Items 972 through 975), with an equal or larger sheave pitch than used on the recovery boom and rated, at a minimum, for 1/2 of the boom rating

· For Items 972 and 973, two adjustable wheel (‘L’) brackets with securing hardware for use with the integrated wheel chocks.