Attachment H Carriers-2010 FederalPurchaseDescription.7.14.09Corrected.doc

FFAH-BB-030700-N

AMENDMENT NO. 1

Rev. July 28, 2003

ATTACHMENT H

CARRIERS

1 July 2009

FEDERAL PURCHASE DESCRIPITON

TRUCKS - LIGHT, MEDIUM, AND HEAVY CARRIERS

WITH HYDRAULIC UNDERLIFT

1 SCOPE AND CLASSIFICATION

1.1 Scope.

This specification defines four standard carriers equipped with a single recovery winch and hydraulic underlift of varying capabilities. See Section 6.2 for definitions.

1.2 Classification.

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

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 Numbers 307, 794 and 807

· GSA Acquisition Manual (GSAM)

· MIL-HDBK-1223, “Non-tactical Wheeled Vehicles Treatment, Painting, Identification Marking and Data Plate Standards”.

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 bidding 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 bids 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, supersedes 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.

3 REQUIREMENTS

3.1 General

The carriers shall be equipped for both recovery and towing. Schematics of the carriers are provided in Figure 1.

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 carrier component. When component or equipment “Capacity” or “Capability” is requested the furnished information shall be as installed on a completed carrier as specified herein, without options. Component or equipment “Capacity” or “Capability” may possibly be limited by other lesser-rated carrier component or equipment. The “Capacity” or “Capability” stated shall also meet the axle loading requirements of SAE J2512 sections 5.9.2 (with a 0.50 “K” factor) and 5.9.3 as applicable.

Figure 1: Graphical representation of key carrier measurements referenced within the body of the federal specification.

3.2 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 required base cab and chassis are defined for each standard item number in Table II. The offered chassis shall comply with all requirements of the referenced Federal Standard Item number except where modified herein. The referenced Federal Standard shall be the version in effect on date of order.

3.2.1 Chassis.

The required CA shall be based on the cab and carrier body length requirements (see Section 3.1.10.1 for cab and Section 3.2.1 for carrier body requirements). A minimum 2” (maximum 4”) gap between the carrier body and the rear of the cab or rear most component shall exist.

3.2.2 Frame.

For each standard item, the frame must resist, without failure, the respective loads at all possible bed positions. 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.

3.2.2.1 Front Bumper. (Delete and Replace With):

A channel type, full-width, front bumper shall be furnished. For Items 978 through 981, the front bumper shall be steel with a corrosion-resistant primer and shall have either 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.

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

3.2.3 Axles.

Axles shall not be overloaded relative to their GAWR ratings under either un-laden or laden (as defined in Sections 3, 3.2.1 and 3.2.3) conditions. Front axle shall have a minimum GAWR equal to that listed. Note: When option HEV is specified consideration will be made concerning additional weight on front/rear axles when determining GAWR. Rear axles shall be single reduction drive axle(s) having a minimum GAWR equal to that listed. For Item 981, a setback front axle shall be furnished according to FSN 3.4.9.

For Items 979 through 981, 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 Item 978, the chassis OEM rear limited-slip differential shall be supplied. For Items 979 through 981, the rear differential ratio shall be selected according to the following maximum geared 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 speed shall be based on SAE J2188 standards. Wind and altitude can be neglected.

For Items 979 through 981, 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 978 shall be deleted.

For Item 978, if Option AWD is specified, the manufacturer’s standard four-wheel drive package will be furnished. 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 979 through 981, 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.

3.2.4 Suspension.

Basic requirements are set forth in the Federal Standards.

For Item 978, 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 979 through 981, the front suspension shall be the chassis manufacturer’s multi-leaf spring suspension, with shock absorbers for GAWRs at or below 14,000 lbs. 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, an air suspension shall be supplied for the rear axle(s). Requirements are set forth in FSN 3.4.8.1.

3.2.5 Brakes.

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

For Item 978, hydraulically controlled disc brakes shall be furnished. A four wheel antilock braking system shall also be installed.

For Items 979 through 981, air actuated, drum brakes with automatic slack adjuster shall be furnished.

3.2.5.1 Compressed Air Supply.

For Items 979 and 980, the engine driven air compressor shall have a minimum flow rating of 13scfm. For Item 981, the engine driven, air compressor shall have a minimum flow rating of 16scfm.

3.2.5.2 Air Dryer.

For Items 979 through 981, 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.

3.2.6 Engine.

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

Air Pollution Control 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.

Minimum acceptable commercial ratings for engine gross brake power and

The provided engine calibration shall have low-idle and high-idle settings equal to that required by the combination PTO/hydraulic pump set point (see Sections 3.2.4.1 and 3.2.4.2).

For Items 979 through 981 an engine automatic shutdown system shall be furnished. The shutdown system shall include low oil pressure, low coolant level, and high coolant temperature automatic shut down with audio and visual alarms with 30 second warning and manual override (see FSN 3.4.19).

Emission certification is required for the ultimate vehicle destination..

3.2.6.1 Compression Brake.

For Items 980 w/YD through 981, when option ECB is specified, an operator controlled, variable compression braking system shall be supplied. A minimum of a three-position in-dash mounted control switch shall be furnished.

3.2.6.2 Engine Block 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 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.

3.2.6.3 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 979 through 981, remote jump-start post(s) shall be mounted in an easily accessible location.

For Item 978, OEM supplied glow plugs shall be furnished to automatically assist in cold-start conditions. For Items 979 through 981, 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.

3.2.6.4 Engine Hour Meter.

When option EHM is specified, an engine hour meter shall be provided. The electronic or mechanical hour meter shall be placed in a readily visible location within the cab.

3.2.6.5 Intake/Exhaust 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 ASI is specified, the air filter shall have a dash mounted, illuminated, resettable Filter Minder® installed per the manufacturer’s recommendations.

For Items 978 through 980, the exhaust system shall be the chassis manufacturer’s standard horizontal stainless or aluminized steel.

For Item 981, 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 at a 90º angle. 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.

3.2.6.6 Cooling System.

A 50% ethylene glycol / water solution shall be used in determining requirements. The antifreeze/coolant solution supplied shall comply with TMC-RP329. Extended Life Coolant (ELC) shall be used if allowed chassis and engine manufacturers. An automatic fan clutch shall be supplied (see FSN 3.4.1.6). 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.

A 50/50 blend of ethylene glycol and water (with corrosion inhibitors) shall be supplied that is acceptable to the engine manufacturer (approximate freeze protection down to –34degF).

3.2.7 Clutch.

For Items 979 and 980 when equipped with manual transmissions, an Eaton Fuller Solo Medium-Duty, Maintenance-Free, 14” diameter, two-plate clutch rated at a minimum of 860lbf-ft, or equal, shall be furnished. For Item 981 with manual transmission, an Eaton Fuller Solo Heavy-Duty, Adjustment-Free, 15.5” diameter, two-plate clutch rated at a minimum of 1,450lbf-ft, or equal, shall be furnished.

3.2.8 Electrical

3.2.8.1 Lighting

Cab/chassis lighting shall adhere to FSN 3.4.2.3 and 3.4.2.4. Daytime running lights shall be provided unless Option DRLD is specified.

3.2.8.2 Alternator.

Chassis OEM installed 12VDC alternator(s) shall be furnished which meet the minimum performance requirements specified.

3.2.8.3 Batteries.

The furnished batteries shall be 12V, high-cycle, and maintenance-free. For Item 978, the chassis OEM dual battery system shall be furnished. For Items 979 and 980, a minimum of three batteries shall be furnished. For Item 981, a minimum of four batteries shall be furnished. For Items 979 through 981, each battery shall have a minimum cold cranking amperage of 625A and a minimum reserve capacity of 180 minutes.

3.2.8.4 Backup Alarm.

An electric type backup alarm that automatically adjusts to ambient noise levels shall be furnished. See FSN 3.4.23 for requirements.

3.2.9 Transmission.

The transmission’s input torque rating shall be equal to or exceed the engine’s peak torque and shall be capable of transmitting the PTO torque required for the operation of the hydraulic pump (see Sections 3.2.4.2). The transmission shall be rated for a minimum of the Item’s 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).

3.2.9.1 Transmission Oil Cooler

For Item 978, the chassis manufacturer’s largest available transmission oil heat exchanger shall be furnished.

For Item 981, the manual transmission shall include a water/oil heat exchanger and an integrated oil pump.

3.2.9.2 Transmission Lubricant

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

3.2.10 Cab.

3.2.10.1 Cab Design.

The cab shall be of conventional design with two doors (see FSN 3.4.12 for requirement details).

For Items 978 through 980, 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 978 through 980, the exterior of the mirrors shall either, be encased in a black composite material or have a black finish coat. For Item 981, 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 cab. See Section 3.3.1 for cab exterior finish requirements.

The windshield shall have tinted glass. A rear cab window shall be furnished. For Item 978, if Option SRG is specified, the rear window shall have a sliding glass feature.

For Item 978, 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 979 through 981, 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 300lb. The steps may be integrated into the battery box or fuel tank(s) in which case they shall be of identical material and finish.

3.2.10.2 Cab Interior. (Delete and Replace With):

Standard seating shall be bucket/captain chairs for both the driver and passenger.

For Item 978, if Option SF is specified, a split front bench seat shall be provided.

For Items 979 through 981, if Option DSS is specified, the driver’s seat shall have air suspension. If Option DSS2 is specified, both the driver’s and passenger seats shall have air suspension.

All seating shall be vinyl. If Option CU is specified, cloth seats shall be provided. Interior color options shall be provided along with the bid for selection by the customer.

For Items 979 and 980, when Option CC is specified, two bench seats shall be provided. The rear bench shall have a fold-forward or fold-up feature. See FSN 3.4.12.2 and 3.4.12.3 for additional requirements.

Air conditioning shall be furnished. If Option DA is specified, air conditioning shall be deleted.

For Item 978, if Option CRTS is specified, tilt steering and cruise control shall be furnished. For Items 979 through 981, a tilting steering column shall be standard.

For Item 978, if Option AP is specified, adjustable pedals shall be furnished.

Intermittent windshield wipers shall be furnished.

If Option PWL is specified, Power windows and door locks shall be furnished.

3.2.10.2.1 Radios.

An OEM AM/FM digital radio with clock shall be furnished as standard. If Option RAD is specified, an OEM AM/FM digital stereo radio with an integrated single CD player and clock shall be furnished.

If Option RACB is specified, a citizen’s band (CB) radio, COBRA 29 WX NW ST, or equal, shall be provided and installed within reach of the driver. Any accessories required for the operation of the radio (i.e., antenna) shall also be furnished and installed

Cab Switches and Gauges.

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

· Speedometer (with odometer and trip odometer)

· Tachometer

· Engine oil pressure gauge

· Coolant temperature gauge

· Voltmeter (Items 979 through 981)

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

· Engine hour meter (Option EHM)

· Air suspension pressure (Items 979 through 981)

· Air cleaner restriction service indicator (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, Item 978)

· 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 981)

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

· Emergency light bar flasher switch and lamp

· Emergency light bar work lights switch and lamp

· Floodlight (underlift) switch and lamp (except for Option DWL or CDS), and

· Parking brake switch and lamp.

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.

3.2.11 Fuel

3.2.11.1 Fuel Tanks.

For Items 979 through 981, if Option FTC is specified, the fuel tank(s) shall have a minimum total capacity of 70gal. 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 operator intervention.

For Items 978 through 981, steel tanks shall be primed or aluminized and have a black finish coat. All tanks shall be baffled and shall have safety and non-spill air vents. Each tank shall be secured under cab with black finish-coated steel bands. Rubber isolators shall be used between the tanks and the bands. Tanks 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.

3.2.11.2 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. Fuel filters shall be spin-on type. An integral primer pump shall be provided on the engine mounted filter if a fuel transfer (lift) pump is not used. The filters shall be placed under the hood in a location allowing unobstructed element replacement.

3.2.11.3 Fuel Water Separator

Items 979 through 981 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 manual drain valve. The separator shall notify the operator when the water container needs to be emptied. See FSN 3.4.1.9(C) for heater performance requirements. The heater shall be thermostatically controlled.

3.2.12 Wheels.

Hub-piloted disc wheels for tubeless tires shall be provided on the front, spare, and rear tire assemblies. Rear, front, and spare wheel size shall be identical for each Item 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 same color as cab.

3.2.13 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. All tires shall be speed rated for a minimum of 75 MPH at the design capacity and pressure. For all Items except 981, drive, spare, and front tires shall be identical.

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 STC is specified, a spare tire carrier shall be furnished. The positioning of the spare tire carrier shall be Government approved.

For Items 979 through 981, if Option CTIS is specified, a central tire inflation system shall be furnished (see FSN 3.1.1.20 for requirements).

3.2.13.1 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.

3.3 Carrier Body and Associated/Auxiliary Hardware.

3.3.2 Carrier Body.

The carrier body shall have a minimum static payload rating equal to that listed in Table XII. The body shall be capable of handling the normal dynamic forces developed by the minimum stated static payloads using the Evenly Distributed Load defined in SAE J2512, Section 5.6.1. The carrier bed shall have a minimum overall width of 95” and a minimum length as specified.

For all Items, if Option CBCL is specified, a concentrated load package shall be furnished. Option CBCL shall enable handling of ½ of the minimum required payload at two load points on the bed. When Option CBCL is selected, the front load point shall be located at 15% of the bed length from the front of the bed and the rear load point shall be located at 50% of the bed length from the front of the bed.

The carrier bed shall be hydraulically controlled. The bed shall be capable of sliding fore and aft on the chassis under maximum rated loading. The bed shall be able to tilt up and down under maximum rated loading, powered in both directions. Sliding and tilting functions shall be independent of each other but shall be capable of being performed simultaneously. Nylatron®, or equal, slide pads shall be used between all sliding surfaces.

The use of a load support mechanism for the bed during deployment is acceptable. If furnished, the operation of the support assembly shall be automatic and shall not interfere with the underlift. If hydraulically controlled, the support assembly shall be able to maintain loading in the event of a hydraulic failure.

On level ground, the approach angle to the lowered bed shall be less than or equal to 15 degrees.

A mechanical bed lock-down feature shall be furnished to retain the loaded bed in the stowed position on the subframe. If tilting of the bed could damage the bed lock-down device, tilt interlocks shall be furnished to prevent inadvertent operation of the tilt cylinders.

The bed shall be capable of transitioning from stowed to fully deployed in 30sec. or less.

For Items 978 and 979, the carrier bed decking shall be a minimum of 1/8” aluminum.

For Item 980, the bed decking shall be constructed of a minimum of 3/16” steel diamond plate.

For Item 981, the carrier bed decking shall be a minimum of 3/16” steel diamond plate over tongue-and-groove or ship-lap joined treated hardwood, or equal. The wood planks shall be 1.25” x 5”, minimum, and shall be treated to resist deterioration and shrinkage according to MIL-HDBK-1223, Section 5.2. Preparation of the treated wood for painting is not required.

For all Items, the bed shall contain: two “T” slots at the outside front; four “T” slots at the rear positioned symmetrically about the bed’s longitudinal axis; and, two outside straight slots able to accommodate one forward and one reward chain in the middle (see Figure 2 for slot geometry examples). The slots shall accommodate the tie-down chains supplied and shall withstand a load in any direction greater than the breaking strength of the supplied chain (see Section 3.2.5).

Figure 2: a) “T” slot, and b) straight slot geometries.

For Items 978 and 979, permanent raised aluminum bed rails shall be furnished. For Items 980 and 981, removable steel bed rails shall be furnished. The bed rail shall be mechanically retained in the bed when in use. A means of securely storing the bed rails on the carrier when not in use shall be furnished. Minimum (installed) rail height for all Items shall be 3” above the deck and railing shall span a minimum of 80% of the bed length.

For all Items, the carrier beds shall be structurally capable of supporting a minimum of 150% of the rated static payloads using the SAE J2512 EDLR (see Section 3.2.2). For all Items, bed crossmember spacing shall be consistent throughout the length of the bed. Crossmembers and carrier subframe shall be constructed of either steel or aluminum. When used together, aluminum and steel body components shall be separated by an inert material other than paint to prevent galvanic corrosion.

The fasteners used to secure the bed to the subframe and the 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.

For all Items furnished with an underlift, a method of storing and securing the safety chains near the tailboard of the carrier shall be furnished.

For Item 981, if Option CBC is specified, a cleated vehicle package for transporting tracked vehicles shall be furnished. Option CBC is intended to assist in the loading of tracked vehicles under very low friction conditions. Offerers shall submit, along with their bid, a proposal for the CBC package. The proposal shall include a dimensioned drawing of the layout and an engineering bill of material for the package. Minimum additional accessories to be furnished with CBC are listed in Section 3.3.8. Option CBCL load requirements shall apply. The bed layout shall include, at a minimum, the following items beyond the base Item 981 requirements:

1. Option CBCL

2. A steel guard to protect the winch and headboard gussets (if furnished) from incidental contact when loading the vehicle or lowering equipment attachments (i.e., dozer blade, bucket, etc.)

3. Three sets (minimum) of outboard, heavy D-rings used for securing the payload. The installed D-rings shall not interfere with the installed side bed rails and shall each be able to withstand a minimum working load of 11,500lbf

4. Two sets of bed slots (minimum) shall be furnished at the front and rear of the bed for securing vehicle attachments, and

5. A removable or self-storing, driver’s side ladder to assist in accessing the front of the carrier bed. A minimum of two steps shall be provided. The ladder assembly and attachment hardware shall support a minimum working load of 300lbf. Provisions for securely stowing the ladder on the carrier shall be furnished. The ladder shall not interfere with closed underbody toolboxes.

When Option DWL or CDS is not specified, a 4-pin receptacle for use with auxiliary tow lights (see Section 3.2.5) shall be installed at the rear of the carrier. A weatherproof, hinged or tethered, corrosion resistant cap shall cover the lighting receptacle.

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

The rear bumper shall be corrosion-resistant, black, and shall meet federal underride (49 CFR 393.86.b) and DOT requirements. Integration of the rear bumper with the underlift or bed support assembly, or dock stabilizer (if furnished) is acceptable.

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.

See Section 3.3.2 for carrier body finish requirements.

For Item 979, when option “B29” is specified, a 29 ft. length body, meeting all applicable body requirements set forth in this document, shall be furnished.

3.3.2.1 Control Stations.

Driver and passenger side carrier controls shall be provided at the rear of the carrier body. These stations shall be lighted and shall allow control of those items used during a recovery effort including, but not limited to, the following labeled items:

Winches (speed control, free-spool (only if air-actuated), forward/reverse)

Carrier bed, and Underlift (or dock stabilizer) (except with Option DWL).

For all Items, a wired or wireless remote control capable of operating the underlift and winch at a minimum distance of 10ft. from the rear of the wrecker shall be furnished.

3.3.2.2 Vehicle Identification Plate and Labels.

A metallic identification plate shall be permanently affixed to the carrier bed, readily visible from the side of the carrier and reflecting the following information:

1. Carrier manufacturer’s model

2. Carrier assembly serial number

3. Front and rear GAWR

4. GVWR

5. Winch line pull rating for full drum

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

7. Wire rope diameter

8. Wire rope length

9. Wire rope working strength

10. Wire rope breaking strength

11. Maximum underlift working tow capacity (if equipped).

A label shall be placed on each side of the carrier bed stating the maximum carrier’s working payload capacity. Labels shall be positioned in front of the control stations when the bed is stowed.

3.3.2.3 Headboard.

For all Items, a standard commercial headboard shall be constructed IAW DOT Crash Protection Standard 49 CFR 393.106- Front End Structure. The headboard shall extend laterally to within 5” of the bed rails and shall extend vertically to within 2” of the top of the cab. The headboard shall be welded or securely fastened using constant torque fasteners and shall meet or exceed 49 CFR 393.106 requirements. When applicable, the steel headboard shall be separated from the aluminum bed by an inert material other than paint to prevent galvanic corrosion.

Neither the top nor middle crossbar of the headboard shall obstruct viewing through the rear cab window. A solid steel plate covering the region defined by the bed surface, the headboard outer tubing, and the middle crossbar shall be furnished to protect the cab. Any access holes placed in the plate shall contain a securely attached black rubber grommet.

Provisions for mounting a lightbar shall be included (see Section 3.2.2.5.3). The lightbar mounting shall provide for unobstructed vision of the lightbar from the front of the truck.

See Section 3.3.2 for headboard finish requirements.

3.3.2.4 Toolboxes.

For Item 978 through 980, a driver’s side toolbox having minimum dimensions of 36”L x 18”W x 18”D shall be installed.

For Item 981, a driver’s and passenger’s side toolbox having minimum dimensions of 48”L x 18”W x 18”D shall be installed.

A minimum of one adjustable shelf shall be supplied with each toolbox.

The toolboxes shall be mounted underbody between the cab and the (front) rear axle. Positioning of the toolboxes shall not interfere with operating devices or restrict access to service items.

The toolbox and shelf shall be constructed from either a minimum of 0.125” aluminum, minimum of 14-gage steel, or a composite material. A minimum of 14 gage steel or stainless steel shall be used for the door. Box panels shall be welded together.

The toolbox shall be weatherproof, lighted, have an integrated stainless steel lock and latch, and interior drains. The box-style door shall be of either open down, to the side, or tuck-away. Lights shall activate upon opening of the toolbox door. The door shall remain open until manually closed by using either stainless steel hinges with a retention device or a tuck-away door. An integral drip rail shall be incorporate at the box top to prevent leakage of liquid into the box when the door is opened.

For all Items, the interior and exterior of the toolboxes shall be black finish coated. For Items 978 through 981, the doors shall have either a black finish coat or polished/chromed finish. Non-stainless steel surfaces shall be primed prior to finish coating or chroming.

For each Item, locks shall be provided for each toolbox and locks shall be keyed identically for each individual vehicle. Two sets of keys (4 keys) shall be provided for each vehicle.

3.3.2.5 Body and Related Electrical

3.3.2.5.1 General Lighting

Carrier body lighting shall adhere to FSN 3.4.2.3 and 3.4.2.4. Carrier body lighting shall be of LED type. All lights shall be sealed in either a stainless steel or polycarbonate housing.

A set of pivotal floodlights shall be provided for underlift illumination. The floodlights shall be located on the right and left side of the underlift below the bed. Floodlights shall be a minimum of a 4” trapezoidal flood, 3,000 candlepower.

If Option DWL or CDS is specified, the ‘underlift’ lights shall be deleted.

All lights shall be weatherproof, encased in black rubber, serviceable, and corrosion resistant.

3.3.2.5.2 Wiring and Electrical Connections.

All wiring shall be in accordance with the applicable requirements of SAE J1292 and J2202. Terminal attachments shall comply with SAE J163, and the terminals themselves must comply with SAE J561 (ring and spade types), SAE J858a (blade type), or SAE J928 (pin and receptacle type). At a minimum, all electrical accessories shall be protected and labeled according to manufacturer standards with resettable circuit breakers or fused links conforming to SAE specifications. Redundant protection is not required. All switches, relays, connectors, and all other electrical components shall be rated for a minimum of 125% of the maximum current for which the circuit is protected.

Wiring shall be permanently color-coded or marked the entire length of the wire for identification with easily read numbers and/or letters. When cables are supplied by a component manufacturer to interconnect system components, the interconnected cables do not need to be continuously color-coded/identified. However, they shall be coded/identified at the termination or interconnection points.

All wiring shall be routed in conduit or high temperature looms with a rating of at least 280 deg F. All conduits, looms, and wiring shall be secured to the body or frame with insulated metal cable straps in order to prevent sagging and movement which results in chafing, pinching, snagging, or any other damage. Cable ties shall not be used to support harnesses but may be used for bundling purposes. The wiring shall be located in accessible, enclosed, protected locations and be kept at least 6” away from exhaust system components. A service loop of wire or harness shall be provided at all electrical components, terminals, and connection points, which permits at least two replacements of the wire(s) termination.

A wiring diagram and schematic shall be included in the service manual.

3.3.2.5.3 Emergency/Auxiliary Lighting.

An emergency lightbar with amber lenses and rear-facing work/tail/brake lights shall be installed upon the top of the headboard. The LED and integrated working lights shall be activated by separate switches in the cab. A double-flash pattern with a firing frequency of 60 – 120 FPM shall be utilized for each LED.

For Items 978 through 980, a 58” Whelen Towman’s 9M Model 9M240W00 or LED equivalent, having four LED , shall be provided. The lightbar flash synchronization shall be programmed as shown in Figure 4 (matching numbers indicate simultaneous flashing).

Figure 4: Lightbar flash synchronization for Items 978 through 980.

For Item 981, a Whelen, 72” Whelen Towman’s 9M Model 9M280W00-9MLTH1 or equal, having eight LED, shall be provided.

The lightbar flash synchronization shall be programmed as shown in Figure 5 (matching numbers indicate simultaneous flashing).

Figure 5: Lightbar flash synchronization for Item 981.

3.3.2.6 Winch and Wire Rope.

The furnished recovery winch 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. One winch shall be furnished per Item. The minimum first layer line pull requirements are listed in Table XIV.

Table XIV: Required minimum winch Ratings.

(lb)

The winch shall contain worm gears, shall be controllable in either direction, and shall be mounted immediately rearward of the headboard. The mounted winch shall be capable of withstanding twice the maximum rated line pull per SAE J706 without damage.

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

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

(lb) Minimum Wire Rope Nominal Breaking Strength Rating

(lb)

7,100

11,820

17,750

35,500

The required minimum length of wire rope is noted in Table XVI.

Table XVI: Required wire rope length and offerings.

Length

(ft) Min. Diameter

(in)

The winch drum shall be capable of storing, in layers, the entire wire rope. All connections and hardware shall have a minimum breaking strength rating equal to that of the rope. A safety hook shall be furnished on the free end of the rope and shall be attached using a Flemish eye splice.

The winch shall contain a drum release clutch. For Items 978 thru 980, the drum release clutch shall be manually activated. For Item 981, the drum release clutch shall be air-actuated. Drum re-engagement shall be automatic upon disengagement of the free-spool control. The winch 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. A rope guide shall be furnished on the top of the leveler with a top-feed winch. A rope guide shall be furnished on the bottom of the leveler with a bottom-feed winch. Side rope guides shall also be furnished. The winch 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 the 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 (see Section 3.5).

3.3.3 Underlift.

For all Items, the hydraulic underlift shall include integrated wheel chocks on the crossbar with manually adjustable wheel (‘L’) brackets (see Section 3.2.5). A provision for securely stowing the ‘L’ brackets when not in use shall be provided. The stowed underlift shall not interfere with the operation of the bed.

The underlift shall be structurally and mechanically capable of lifting the minimum 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. Measurement is from the rear of the end of the carrier bed at the centerline per SAE J2512, Section 5.7.

If Option CWLL is specified, the underlift shall allow horizontal pickup relative to the ground for towing vehicles with low ground effects.

If Option CDS is specified, a hydraulically actuated rear dock stabilizer shall be furnished in lieu of an underlift. The dock stabilizer shall be capable of supporting the bed with the maximum offered payload for the Item with the bed fully extended.

For all Items, the underlift (dock stabilizer) shall be capable of extending from its fully retracted position to fully extended 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 ±5deg relative to the horizontal.

All underlift functions shall be independently controlled and capable of simultaneous operation.

The underlift assembly shall be secured to the vehicle’s frame or subframe. The securing hardware shall be capable of withstanding 150% of the maximum allowed bending moment. The underlift assembly shall also meet all strength requirements of 49 CFR 393.71.h.

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

If Option DWL is specified, the underlift shall not be furnished.

3.3.3.1 Lifting/Towing Capabilities.

The carrier’s lift/tow load capabilities shall be defined as the weights that can actually be lifted and towed by the carrier using the underlift, with a representative load on the bed. For the purposes of these calculations, the applied load on the bed shall be 3,400lbs, with a CG at a distance of 90 inches rearward from the front of the bed, centered laterally on the bed. Given this bed loading, for each Item, the offeror shall determine the resultant remaining underlift lift and tow capacities on the offered carrier.

Lifting of the stated lift load (at LP) 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, the stipulated 3,400 lb.