2015_Fed_Std_794AH_and_807W_08.09.2014.pdf

Combined Fed Std 794AH Fed Std 807W

Aug 9, 2014 Superseding

Fed Std 794AG Fed Std 807V

Aug 9, 2013

FEDERAL STANDARD

TRUCKS AND TRUCK TRACTORS: Medium and Heavy Commercial 19,501 pounds and greater Gross Vehicle Weight Rating

1. SCOPE AND CLASSIFICATION

1.1 PURPOSE.

This document covers new commercially produced classes 6, 7 and 8 trucks. The groupings are based on the Department of Transportation Federal Highway Administration (FHWA). It is intended to simplify competitive procurement of commercial vehicles, and achieve a practical degree of standardization within the federal fleet.

1.2 APPLICATION.

This Federal Standard does not include all the varieties of the commodity indicated by the title but is intended to cover only those vehicles generally acquired competitively by the Government. This standard highlights, in concise form, types of trucks with standardized components and equipment. A selection of coded optional additional systems and equipment is included for divergent geographic and operational related needs. Vehicles must meet the integrated requirements of the individual item and the detailed paragraphs (see section 3). The requirements of the standard may be tailored to meet unusual operating conditions, to incorporate special purpose equipment, and to provide for exceptions not otherwise covered.

These trucks are warranted by the contractor/supplier upon delivery as specified in this standard.

Vehicle procurement must comply with the Federal Property Management Regulations (FPMR) and the Federal Procurement Regulations (FPR).

1.3 COVERAGE OF TRUCK TYPES.

The types of vehicles covered by this standard are listed below. Additional optional equipment is available.

Figure 1. Types and Classes

TYPE CLASS

Cab and Chassis 6, 7 and 8 Dump 6, 7 and 8 Refrigerated Van 6, 7 and 8 Stakes 6, 7 and 8 Truck Tractors 6, 7 and 8 Dry Van 6, 7 and 8 Forestry 6 Maintenance Body 6 and 7

1.4 CLASSIFICATION.

The vehicle(s) are divided into “Classes.” The “Class” of vehicle(s) shall be determined by the minimum gross vehicle weight rating (GVWR) as follows:

CLASS 6 7 8

(LBS) 19,501-26,000 26,001-33,000 33,000 - above

1.5 RESERVED.

1.6 STANDARD TRUCK AND ALTERNATE COMPONENTS.

The standard truck shown as a “numbered item” in Autochoice/Autostandards Data and components listed as a “GSA Min Req” in with each such Item are minimum requirements and acceptable equipment. The components designated as “Minimum Requirements” shall be furnished in accordance with the referenced specification. A selection of alternate options and equipment is listed under “Options” with each Item. Selected optional equipment shall be furnished when the code(s) are specified.

2. APPLICABLE DOCUMENTS

2.1 GENERAL SERVICES ADMINISTRATION STANDARD REQUIREMENTS DOCUMENTS

The complete set of requirements for products required under this Standard is divided into two parts.

The first (Part A) is this written document which establishes the foundation for the products the GSA is requesting. Part B is a set of requirements specific to individual Standard Items shown/listed in a web based application referred to as AutoChoice.

2.1.1 SPECIFICATIONS, STANDARDS, AND HANDBOOKS.

The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto, in effect on date of solicitation.

COMMERCIAL ITEM DESCRIPTIONS

A-A-55439 Battery, Storage: Vehicular, Ignition, Lighting and Starting.

A-A-50271 Plate, Identification, instruction and marking.

HANDBOOKS

MIL-HDBK–1223 Nontactical Wheeled Vehicles Treatment, Painting, Identification Marking, and Data Plate Standard.

MIL-HDBK–1791 .... Designing for Internal Aerial Delivery in Fixed Wing Aircraft

DH-1-11AFSC Design Handbook.

SPECIFICATIONS

MILITARY

MIL-T-5624 Turbine Fuel, Aviation, Grades JP - 4 and JP-5.

MIL-T-83133 Turbine Fuel, Aviation, Kerosene Type, Grade JP-8.

MIL-PRE-20696 Cloth, Waterproof, Weather Resistant.

STANDARDS

FEDERAL

FED-STD-297 Rustproofing of Commercial (Nontactical) Vehicles.

MILITARY

MIL-STD-209 Lifting and Tiedown Provisions

MS 75020 Connector, Plug, Electrical - 12 Contact, Intervehicular, 28-Volt, Waterproof.

MS 75021 Connector, Receptacle, Electrical - 12 Contact, Intervehicular, 28-Volt, Waterproof.

Unless otherwise indicated, copies of federal and military specifications, standards, and handbooks are available from:

Naval Publications and Forms Center Military Specifications and Standard, Bldg. 4D 700 Robbins Avenue Philadelphia, PA 19111-5094

2.1.2 OTHER GOVERNMENT DOCUMENTS, DRAWINGS, AND PUBLICATIONS.

The following other Government document, drawings, and publications form a part of this specification to the extent specified herein. Unless otherwise specified, the issues are those in effect on date of solicitation.

Department of Commerce (DOC)

Voluntary Product Standard PS 1-95 Construction and Industrial Plywood

Copies of DOC publications can be ordered on the following web address: http://www.gpo.gov/

DEPARTMENT OF TRANSPORTATION (DOT)

Federal Motor Carrier Safety Regulations.

Federal Motor Vehicle Safety Standards.

Copies of DOT publications can be ordered on the following web address: http://www.gpo.gov/

Copies of the Code of Federal Regulations, 49 CFR, and the Federal Register, can be ordered on the following web address: http://www.gpo.gov/

ENVIRONMENTAL PROTECTION AGENCY (EPA)

Control of Air Pollution from New Motor Vehicles and New Motor Vehicle Engines.

Noise Emission Standards for Transportation Equipment - Medium and Heavy Trucks.

Copies of EPA publications can be ordered on the following web address: http://www.gpo.gov/

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Subpart N Cranes, Derricks, Hoists, Elevators, and Conveyors.

Copies of OSHA publications can be ordered on the following web address: http://www.gpo.gov/

2.2 NON-GOVERNMENT PUBLICATIONS.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, documents that are DOD adopted are those listed in the issue of the DODISS specified in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents in effect on the date of solicitation.

THE EUROPEAN TYRE AND RIM TECHNICAL ORGANIZATION (ETRTO)

Standards Manual.

Application for copies of the ETRTO publication should be addressed to:

European Tyre and Rim Technical Organizations 32, Avenue Brugman 1060 Brussels, Belgium

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA No. 70 National Electric Code.

Application for copies of NFPA publications should be addressed to:

The National Fire Association Batterymarch Park Quincy, MA 02269

NATIONAL TRUCK EQUIPMENT ASSOCIATION (NTEA)

Conversion Hoist Chart.

Dump Body Hoist Chart.

Application for copies of NTEA publications should be addressed to:

National Truck Equipment Association 38705 Seven Mile Road, Suite 345 Livonia, MI 48152

SAE, INC.

SAE Standards and Recommended Practices

J318 Air Brake Gladhand Service (Control) and Emergency (Supply) Line Couplers -Trucks, Truck-Tractors, and Trailers (DOD adopted).

J350 Spark Arrester Test Procedure for Medium Size Engines (DOD adopted).

J516 Hydraulic Hose Fittings.

J517 Hydraulic Hose.

J537 Storage Batteries.

J551 Performance Levels and Methods Measurement of Electromagnetic Radiation from Vehicles and Devices (30-1000 MHz).

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

J682 Rear Wheel Splash and Stone Throw Protection (DOD adopted).

J683 Tire Chain Clearance - Trucks, Buses, and Combinations of Vehicles.

J700 Upper Coupler Kingpin - Commercial Trailers and Semi trailers.

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

J844 Nonmetallic Air Brake System Tubing (DOD adopted).

J994 Alarm- Backup- Electric.

J1067 Seven-Conductor Jacketed Cable for Truck-Trailer Connections.

J2188 Truck Ability Prediction Procedure (DOD adopted).

J2394 Seven Conductor Cable for ABS Power – Truck and Bus

(Application for copies of SAE publication should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale, PA 15096.)

THE TIRE AND RIM ASSOCIATION, INC.

Year Book.

Application for copies of Tire and Rim Association publication should be addressed to:

Tire and Rim Association, Inc., 175 Montrose West Avenue Copley, OH 44321

THE MAINTENANCE COUNCIL (TMC).

Recommended Maintenance Practices Manual

RP 105B Battery Cable Assemblies RP 109A Battery Ratings and Engine Cranking Requirements RP 111B Circuit Protections RP 112 Terminals for Heavy Duty Truck-Tractor Primary Wiring Systems RP 113A Electrical Systems Connectors RP 114A Harness Protection RP 118A Turn Signal Switches RP 120A Wiring Systems Identification RP 137 Antilock electrical supply for tractors through SAE J560 seven pin connector RP 138 Auxiliary forward lighting.

RP 321 Fuel Crossover Line Protection and Configuration Guidelines RP 325 Radiator Integrity for Highway Trucks RP 329 Specifications for Ethylene Glycol Base Coolant Containing Nitrite RP 403 Placement of Safety Equipment RP 404B Truck and Tractor Access System RP 417 Supporting pneumatic electrical lines between cab and trailer.

RP 418 Heavy-duty, in-cab R134A air conditioning systems RP 624 Synthetic Lubricants RP 637 Air Dryer Guidelines RP 710 Overhead door selection RP 711 12 year life swing - type freight van, trailer doors

Applications for copies of TMC publications should be addressed to:

The Maintenance Council American Trucking Associations 2200 Mill Road Alexandria, VA 22314-5388.)

2.3 ORDER OF PRECEDENCE.

Nothing in the Federal Standard supersedes applicable laws and regulations unless a specified exemption has been obtained.

2.4 ABBREVIATIONS AND DEFINITIONS.

Following are the abbreviations or contractions and their meanings as they appear and are used in this standard:

ABBREVIATIONS DEFINITIONS

AMP .................. AMPERE

AT ..................... ALL TERRAIN TIRES

AUX .................. AUXILIARY

BAT .................. BATTERY

BBC .................. FRONT BUMPER TO BACK OF CAB

CA .................... CAB TO CENTER OF REAR TANDEM

CAP .................. CAPACITY

CM .................... CENTIMETERS

CYL .................. CYLINDERS

DIA ................... DIAMETER (IN INCHES)

FC ..................... FORWARD CONTROL

FT ..................... FOOT OR FEET

FRT .................. FRONT

GAS .................. GASOLINE

GAWR .............. GROSS AXLE WEIGHT RATING

GCWR .............. GROSS COMBINED WEIGHT RATING

GHP .................. GROSS HORSEPOWER

GVWR .............. GROSS VEHICLE WEIGHT RATING

H.D. .................. HEAVY DUTY

H.D.A. ............... HEAVIEST DUTY AVAILABLE

HWY ................. HIGHWAY

HYD .................. HYDRAULIC

IN ...................... INCHES

KG .................... KILOGRAMS

L ....................... LITERS

LBS ................... POUNDS

M ...................... METERS

MAN ................. MANUAL

MAX .................. MAXIMUM

MFR .................. MANUFACTURER’S

MIN ................... MINIMUM

MPG ................. MILES PER GALLON

MSPC ............... MFR. STD. PAINT COLOR

N/A ................... NOT APPLICABLE OR NOT AVAILABLE

ABBREVIATIONS DEFINITIONS

NHP .................. NET HORSEPOWER

OEM ................. ORIGINAL EQUIPMENT MANUFACTURER

OO .................... ON-OFF ROAD TIRES

OPT .................. OPTION, OPTIONAL

PASS ................ PASSENGERS

PTO .................. POWER TAKEOFF OPENING

RAD .................. RADIAL

RBM ................. RESISTING BENDING MOMENT

SPD .................. SPEED

STD .................. STANDARD (SPECIFICATIONS)

V ....................... V-TYPE (ENGINE)

W/, & W/O ........ WITH, AND WITHOUT

/ ........................ AND

3 REQUIREMENTS.

3.1 STANDARD VEHICLE AND ACCESSORIES.

The vehicle, components, assemblies, and accessories to be delivered under the contract shall be standard or additional items, which meet or exceed the requirements of this standard and as described in the associated GSA PDF Files. No removal, substitution or alteration of the chassis manufacturer’s standard or optional chassis model components shall be made except as detailed herein. All chassis items shall be as represented in the chassis manufacturer’s technical data book.

Special bodies or mounted equipment shall be as represented in the body and equipment manufacturer’s technical data. Capacities shall not exceed those published in the manufacturers’ technical data. Technical data shall be limited to specifications and technical material, identical to that furnished to the authorized company representatives for selection of vehicle models and components, and shall be available to the engineering offices of the procuring activity, prior to delivery of the items. The chassis model furnished shall be not older than the chassis manufacturer’s current model on the date of invitation for bids.

3.1.1 SPECIAL REQUIREMENTS.

In addition to the standard vehicle and components specified in 3.1, the vehicle shall be furnished with special equipment as specified herein.

3.1.1.1 TREATMENT AND PAINTING.

The vehicle body, including compartments, doors, and tool boxes, except bright finish aluminum and stainless steel, shall be treated and painted in accordance with MIL-HDBK-1223. The interior of dump bodies need not be painted. The manufacturer’s standard treatment and painting for cab and chassis is acceptable. Unless otherwise specified, the exterior color shall be the brightest white available from the manufacturer’s colors. When specified, color selection will be made after contract award from the standard color charts to be supplied by the manufacturer.

3.1.1.2 DRAIN PLUGS.

Drain plugs installed in manual transmissions, transfer case and rear axles shall be of the permanent magnet type.

3.1.1.3 WOOD TREATMENT

Unless otherwise specified, the manufacturer’s standard wood treatment is acceptable. Soft wood shall be pressure treated with a wood preservative and undercoated when directly exposed to exterior moisture such as under van bodies. Hardwood does not to be treated on top surface when used for stake bed decking. When specified, wood shall be treated in accordance with MIL- HDBK-1223.

3.1.1.4 TOWING DEVICES

When required as a Minimum, towing devices consisting of two hooks, loops, eyes or pins or the chassis manufacturer’s standard single center mounted eye or pin shall be mounted on the front of the vehicle. All towing devices shall be frame rail mounted or reinforced back to each frame rail.

3.1.1.5 WHEEL SPLASH AND STONE THROW PROTECTION

Stakes and dumps shall have rubber mud flaps to the rear of the rear wheels. Tractors shall have rigid quarter fenders to the front of the rear wheels and rubber mud flaps to the rear of the rear wheels. Tractor mud flaps and their extension supports shall be readily removable, to increase landing wheel clearance, without the use of hand tools. A metal strip not less than 3.2 mm (0.125 in) thick and not less than 25 mm (1 in) wide, extending the entire width of the mud flap, shall be installed to prevent the bolt heads or bolt nuts from damaging the mud flap. As an alternate method of attaching the mud flaps, tabs or clips with minimum surface contact dimensions of 25 mm (1 in) high by 32 mm (1.25 in) wide by 2.4 mm (0.094 in) thick shall be furnished at each bolt. All tilt cabs shall have rubber mud flaps to the rear of the front wheels. All splash shield and mud flap installations, front and rear, shall conform to the rear splash and stone throw protection provisions of SAE J682.

The quarter fenders on tractors need extend down only to the height of the centerline of the rear axle.

Splash shields shall have no advertising or logos, except that of chassis or body manufacturer. Tires shall not protrude beyond the front fenders. Composite rubber fender extensions can be added to properly cover the tires.

3.1.1.6 BRUSH GUARD

6x6 and 4x4 vehicles shall be equipped with a radiator and headlamp brush guard.

3.1.1.7 4X4, 6X6 CONVERSION

The chassis manufacturer’s standard truck chassis may be modified to provide all-wheel drive conforming to the requirements specified herein if:

(a) The conversion axle manufacturer specifically approves and certifies that all such modifications meet the design requirements and standards of the conversion axle manufacturer. Certification shall be based on both design analysis and proving ground test reports.

(b) The chassis manufacturer’s front axle rating before conversion is not exceeded by the conversion axle to be installed.

(c) Components used in the all-wheel drive conversion are of current production.

(d) Components used in the all-wheel drive conversion are approved for the conversion application by the component manufacturers.

(e) The converted vehicle is certified to conform to Federal Motor Vehicle Safety Standard No. 121 by the intermediate or final manufacturer.

(f) Replacement headlights, if required to be added, shall meet the height requirement of not less than 560 mm (22 inches) and not more than 1370 mm (54 inches), measured above the road surface, in conformance with Federal Motor Vehicle Safety Standard No. 108. Replacement headlights shall be equivalent in mounting, protection, range and precision of adjustment to the chassis manufacturer’s original standard headlights.

(g) Unused headlight cavities are covered in a neat workmanlike manner, treated and painted to match the chassis cab color with treatment and painting equivalent to the chassis cab manufacturer’s process for the remainder of the chassis cab.

(h) Complete installation drawings for the specific chassis are available.

(i) Warranty and parts service is available at a facility no more distant than the chassis manufacturers nearest authorized dealer.

3.1.2 ELECTRICAL COMPONENTS FOR TRUCK BODIES AND ACCESSORY EQUIPMENT

Truck bodies and accessory equipment shall conform to TMC RP 105B, RP 111B, RP 112, RP 113A, RP 114A, and RP 120A when applicable.

3.1.2.1 BRAKE LIGHTS

At least one pair of brake lights shall override the four-way emergency flasher or the two systems shall be independent of each other. Modifications to the manufacturer’s standard product to accommodate this requirement shall not compromise conformance to any Federal Motor Carrier Safety Regulation referenced herein or to any Federal Motor Vehicle Safety Standard. If additional lights are added to the vehicle, the lights shall be selected from the chassis manufacturer’s standard matching hardware. On truck tractors, the brake lights need to override the four-way flasher only when coupled to a semitrailer, in accordance with TMC RP 118A.

3.1.3 HYDRAULIC SYSTEM GENERAL REQUIREMENTS

The following requirements shall apply to vocational hydraulic systems installed on vehicles covered by this Standard.

A. Drive systems.

Hydraulic pumps shall be driven by one of the following:

1. Transmission mounted PTO. Pumps shall be flange mounted to the transmission. An extended shaft PTO mount can be used to move the pump toward the back of the transmission to improve serviceability and clearance. A u-joint system must not be used unless specifically allowed by the GSA.

2. Electric motor driven pumps can only be used to power hydraulic liftgates.

3. Engine crankshaft driven front power take off, integral frame extensions and OEM approved and furnished chassis for front PTO shall be used.

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

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

85.1714

50.1

PV

= Minimum PTO HP Rating

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

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

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

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

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

1. Hydraulic hoses shall be rubber covered double wire braid reinforced and comply with SAE 100R2, Type A or AT, or 100R9, type A or AT, of SAE J517. The working pressure of the hose shall exceed the pressure setting of the relief valve. Hoses shall be sized such that the maximum velocity of hydraulic fluid in the hose does not exceed the following:

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

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

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

SAE J1273

3. System working pressures shall not exceed the maximum pressure of the powered devices or 3500 PSI if a consumer is not furnished as part of the vehicle order or no maximum pressure value is provided by the ordering agency. A system pressure test port shall be provided. The test port shall be located so that the maximum pressure produced by the system can be monitored without disconnecting any component of the system.

4. Hydraulically actuated implements, such as snowplows, which are deployed while the vehicle is moving, shall be furnished with an automatic reset breakaway mechanism to prevent hydraulic shock if the implement strikes an obstruction while the vehicle is in operation.

5. Hydraulic hose fittings shall comply with the requirements of SAE J516 for permanently attached (crimped) fittings with JIC 37° flare. Field replaceable type fittings are not acceptable. Forged steel hydraulic adapters shall be used. Cast steel fittings are not acceptable.

C. Pressure protection

All hydraulic systems shall be furnished with a pressure relief valve. The relief valve shall be used for overpressure protection only and shall not be used for any flow control purpose. In no case shall a relief valve be set at a pressure higher than the working pressure of the lowest rated component (hose, coupler, adapter, cylinder, etc.) in the system. As a minimum the system must be a three line flow type with one pressure out, one return to reservoir, and a filtered bypass return.

D. Flow control valves

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

E. Fluid filtration

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

F. Hydraulic system cooling

Hydraulic systems shall be designed to operate in ambient temperatures ranging from –20 deg F to +120 deg F.

The hydraulic system shall be designed such that the maximum hydraulic oil temperature does not exceed 200 deg. F. For continuously driven devices, such as spreaders and other motor driven applications, auxiliary cooling, such as air-to-oil coolers or water-to-oil coolers, shall be furnished if required to meet the maximum oil temperature requirement. The government reserves the right to request and be furnished test documents showing maximum stabilized temperatures of hydraulic systems.

G. Hydraulic reservoirs

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

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

2. The reservoir shall be furnished with minimum ¾ in. air filtration type breather or combination breather cap with not greater than 10-micron air born particle rating.

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

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

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

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

H. Hydraulic oil Hydraulic oils shall meet the minimum requirements of the hydraulic pump or other critical component manufacturer(s) for all season use. Water based hydraulic fluids shall not be used.

A nameplate shall be affixed near the fill cap on the reservoir indicating the type of oil to be used. Automatic transmission fluids and motor oils shall not be used in any system unless specifically called for by the hydraulic components and system manufacturer.

I. Hydraulic pumps

For dump hoists, a gear type dump pump must be used when no other hydraulic equipment is added which requires hydraulic power from the primary pump. For dump trucks of 10 yards or more and when a single line wet kit is required by option a Heavy Motions Model PC 102 LAS, Permco DM 25 or Parker C102 pump shall be furnished. The pump shall have an output of not less than 27 gpm @1,000 rpm and 2,500 psi. For dumps less than 10 yards a lesser capacity dump pump can be furnished but in all cases the system performance criteria must be met. The maximum governed engine speed while the hoist PTO is active must not allow the pump speed to exceed 1,200 rpm. For dump hoist applications where an auxiliary hydraulic device such as a spreader is required by option, the pump used shall be a variable displacement load sensing piston pump. Pump displacement must be 6.10 cu in/rev or larger and a GPM of 54 GPM or greater and a maximum rated speed of not less than 2000 rpm. The variable displacement pump provided must be able to meet the system performance requirements of the hoist and provide full power operation of any tailgate spreader required by option. When a slip in spreader is required by option the pump must meet the load demands of all motors on the spreader with those motors operating at full speed.

J. System performance

All body hoists must rise from resting position to full extension in 30 seconds or less in temperature conditions greater than 40 degrees Fahrenheit. The hoist must also return from full extension to resting in no more than 30 seconds.

K. Hydraulic hoist The hoist for all dump truck bodies 10 yards and over shall be a telescopic type. For all dumps less than 10 yards and for stake body and forestry bodies, the hoist can be a scissor type lift mechanism. Hoist hydraulic cylinders shall be chrome plated. The hoist shall lift the body to a minimum dumping angle of 50 degrees (+1, -2) from the top of the truck chassis frame. The hoist shall be capable of lowering the raised body by gravity when the pump is disabled. A two-position lever or a two-speed hoist lowering valve to provide “feather down” capability shall be provided.

A mechanical safety lock permanently affixed to the body or hoist shall be furnished. The safety lock shall provide positive retention of the body with the body in the up position for servicing or repair. Safety lock mechanism shall not interfere with the operation of the body under any operating conditions.

The following NTEA hoist class ratings apply to dump body hoists only. The following class and cubic yard capacities are minimum requirements unless otherwise stated:

Cubic Yards NTEA Class

2 40

3 40

4 40

5 50

6 50

7 50

8 60

9 60

10 60

11 70

12 80

13 110

14 110

15 120

16 120

17 120

18 120

K. Installation and workmanship

The hydraulic system shall comply with the following requirements:

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

Teflon tape is not acceptable.

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

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

apart.

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

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

a. Tensile loads on the hose

b. Side loads

c. Flattening

d. Kinking

e. Thread damage

f. Damage to sealing surfaces

g. Abrasion

h. Twisting

i. Exceeding minimum hose bend radius

j. Operational Test

k. The hydraulic system and hydraulically driven components shall be operated and checked for leaks and proper operation. The operational test shall include the maximum requirements (height, extension, speed, etc.) of the driven devices under no-load conditions. No leakage is permitted beyond a class “1” leak in accordance with SAE J1176-External Leakage Classifications for Hydraulic Systems.

3.2 GENERAL DESIGN

3.2.1 FEDERAL MOTOR VEHICLE SAFETY STANDARDS

The vehicle furnished accessories shall comply with all Federal Motor Vehicle Safety Standards in effect on the date of manufacture.

3.2.2 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.

3.2.3 SOUND LEVEL

The cab interior sound level shall not exceed 84 db(A) when measured in accordance with Federal Motor Carrier Safety Regulation 393.94. The vehicle exterior sound level shall conform to the Environmental Protection Agency Noise Emission Standards for Transportation Equipment, Medium and Heavy Trucks.

3.2.4 CURB WEIGHT

The curb weight is defined as the empty weight (no payload included) of a fully equipped truck. Curb weight shall include the chassis-cab, body, all attached devices, equipment, and full complement of fuel, lubricants, and coolants.

3.2.5 GROSS VEHICLE WEIGHT

The gross vehicle weight (GVW) shall consist of the curb weight, operator and passenger weight computed at 175 lb each and a payload to provide not more than the specified GVWR.

3.2.6 WEIGHT DISTRIBUTION

The distribution of GVW for the purpose of establishing suspension, axle and tire capacities shall be determined with the payload uniformly distributed over the load area. For tractors furnished with a sliding fifth wheel, the weight distribution shall be determined with the sliding fifth wheel in its most forward position of adjustment.

3.2.7 GROSS COMBINATION WEIGHT

Gross combination weight (GCW) shall consist of the truck or truck tractor curb weight, operator and passenger weight computed at 175 lb each, and the weight of a trailer loaded to provide not less than the specified GCW. The fifth wheel shall be located so that with the truck tractor loaded to GVWR, the load rating of the chassis components are not exceeded.

3.2.8 RATINGS

Vehicle ratings shall be the manufacturer’s published ratings. Component and vehicular ratings shall not be raised to meet the requirement of this specification.

3.2.10 ACCESSIBILITY

The design of the vehicle and optional equipment shall permit access for routine servicing and shall permit access for replacement and adjustment of component parts and accessories with minimal disturbance of other components and systems.

3.2.11 RECOVERED MATERIALS / REGULATORY REQUIREMENTS

In accordance with Section 23.403 of the Federal Acquisition Regulations, the Government’s policy is to acquire items composed of the highest percentage of recovered materials practicable, consistent with maintaining a satisfactory level of competition without adversely affecting performance requirements or exposing supplier’s employees to undue hazards from the recovered materials. The term “recovered materials” means materials that have been collected or recovered from solid waste and reprocessed to become a source of raw materials, as opposed to virgin raw materials. None of the above shall be interpreted to mean that the use of used or rebuilt products is allowed under this document. The use of re-refined oil shall not be prohibited. This does not prohibit vehicle manufacturers from using performance criteria for acceptable oil. Any re-refined oil products shall meet the performance criteria of the vehicle and component manufacturers.

3.3 PERFORMANCE

3.3.1 MAXIMUM VEHICLE SPEED

The maximum vehicle governed speed shall be not less than 70 mph (65mph for 4x4 and 6x6) or more than 75 mph. Under no circumstance shall the vehicle maximum governed speed exceed the speed rating of any of the furnished tires.

3.4 CHASSIS COMPONENTS

3.4.1 ENGINE

The engine furnished for the specified vehicle class shall be the chassis manufacturer’s standard or optional engine for the commercial model truck that meets or exceeds the requirements of this specification.

3.4.1.4 COOLING SYSTEM

a. Cooling system shall be charged with extended life coolant and protected not less than -34 degrees Fahrenheit.

b. The cooling system coolant protection level must be furnished. A label indicating the required coolant type must be placed within close visible proximity to the coolant reservoir.

c. Tilt cab models must have an access door if needed to provide verification of the cooling system.

d. All coolant hoses and lines shall meet or exceed the requirements of SAE J20 D2.

e. All hoses and lines shall be securely attached with constant-tension, or thermoplastic clamps.

Hoses and lines shall not be permitted to rub components that may eventually lead to a coolant leak.

f. Hoses and lines shall not be supported by wire ties or straps.

3.4.1.5 COOLANT TEMPERATURE CONTROL

Thermostatic control of engine coolant temperature shall be provided. Control shall include complete thermostatic control of all coolant flow through the radiator.

3.4.1.7 ENGINE BLOCK HEATER

An engine block heater of the OEM chassis manufacturer’s 110/120 VAC design shall be furnished.

A 25 ft long commercial grade outdoor rated power cable with inline automatic reset Ground Fault Circuit Interrupter (GFCI) shall be furnished. The furnished cable shall be UL Listed and rated no less than 10% greater than the maximum capacity of the furnished block heater.

3.4.1.8 FAN CLUTCH

A fan clutch shall be provided. The fan clutch shall reduce the fan speed automatically when the fan is not required for engine cooling. The fan clutch shall be asbestos free.

3.4.1.9 ELECTRONIC THROTTLE CONTROL

An electronic hand throttle control with quick release shall be furnished.

3.4.2 ELECTRICAL SYSTEM

The electrical system shall be in accordance with Federal Motor Carrier Safety Regulations 393.27 through 393.31 and 393.33.

3.4.2.1 STARTING SYSTEM

A 12-volt engine starting system, with 12-volt direct current (DC) lighting system shall be furnished.

Easily accessible remote jump - start post(s) shall be furnished, within close proximity to the battery box. Posts shall be furnished with protective rubber or plastic type covers that are tethered to prevent loss. Jump posts not required on electric or hybrid vehicles.

3.4.2.2 ALTERNATOR

The maximum alternator RPM rating shall not be exceeded at the top governed engine RPM. The output values must meet or exceed those listed in the Minimum Requirements for each Standard Item.

3.4.2.3 LIGHTING

a. All vehicle lights, reflectors, and wiring shall conform to Federal Motor Carrier Safety

Regulations.

b. All stop, tail, directional, rear tag, and marker lights shall be light emitting diodes unless otherwise specified.

c. LED lights shall be installed with tamper resistant hardware.

d. LED lighting shall have internal voltage regulation.

e. All exterior lights shall be grounded with an insulated wire.

f. The ground lead shall not be secured by the lamp fixture mounting screws or hardware.

g. A terminal shall be attached to the wires by a simple mechanical crimp-type process that conforms to SAE J163.

h. Ground terminal lugs shall be solder plated, cadmium, tin or zinc plated.

i. Ground terminals should be clustered and shall be accessible for servicing.

j. A serrated paint-cutting terminal shall be utilized to make proper contact when used on painted surfaces.

k. When two wire lights are not commercially available, then ground return connections may be made to vehicle structure, frame or engine using the ground-return system (one wire systems per SAE J1292).

l. All lights or powered components mounted on hinged covers or doors shall have a flex loop secured at both ends to allow for normal opening of cover without damaging wires.

m. Clearance lamps shall be low-profile design or body recessed to prevent damage from tree limbs. Armor shields shall not be supplied to protect lighting unless supplied commercially as standard equipment.

n. All exterior housings of lamps, switches, electronic devices, and fixtures shall be corrosion resistant and weatherproofed.

o. Daytime running lights shall be furnished, in accordance with FMVSS 108, and TMC RP

138. Truck bodies shall be furnished with conspicuity markings in accordance with FMVSS 49 CFR Part 571.108.

p. All tractors must be equipped with at least one white lamp behind the cab to illuminate the trailer hose and cable connection area.

3.4.2.4 TURN SIGNALS

Temporary mounting for rear signal units shall be provided on chassis models. Turn signals shall conform to TMC RP 118A.

3.4.2.5 LIGHTING CABLE FOR TRUCK TRACTOR

The semitrailer lighting cable for tractors shall conform to SAE J1067. The cable shall incorporate a connector conforming to SAE J560 on the semitrailer end. The cable shall be coiled and shall have an extended length of not less than 110 inches. The SAE J560 connector shall include a grip for withdrawing from the semitrailer receptacle. Stowage for the cable shall be provided by the means of a hook and hanging loop or a protective holding bracket. When the hook and loop method is used, the cable shall be so attached as to ensure that the plug is pointed down when the cable is stowed.

Unless otherwise specified, stowage shall be by:

(a) A hook provided on the rear of the truck tractor cab.

(b) A hook on a pogo-stick type hose tender.

(c) A protective bracket mounted at the rear of the cab below the roofline. Each shall hold the cable plug so as to prevent water from entering the terminals. The lighting cable; when on the hook, loop or protective bracket; shall be accessible to an operator standing on the ground to the rear of the cab, on the street side of the vehicle.

3.4.2.6 BATTERIES

Each battery shall be of 12-volt potential. The total reserve capacity ratings and the total cold cranking ampere ratings at -18°C (0°F), both measured in accordance with SAE J537. The batteries shall be of the maintenance-free type having the maintenance-free characteristics listed in A-A- 55439. Batteries shall conform to TMC RP 109A.

3.4.2.7 RADIO INTERFERENCE SUPPRESSION

The vehicle shall be suppressed to limit electromagnetic radiation in accordance with SAE J551.

Body equipment emitting electromagnetic radiation shall be suppressed to the same level as the vehicle chassis.

3.4.3 FUEL SYSTEM

The fuel system shall conform to Federal Motor Carrier Safety Regulations 393.65 and 393.67.

3.4.3.1 AIR CLEANER

Dry type with manual reset, progressive type air restriction indicator included in the engine intake air system

3.4.3.2 FUEL TANK(S)

When more than one fuel tank is furnished on diesel engine driven vehicles, means shall be provided to assure equalized fuel level in both tanks. When fuel crossover lines are furnished they shall be in accordance with TMC RP 321. When more than one tank is furnished on gasoline engine driven vehicles, a selector valve connecting either tank to engine fuel intake shall be provided and means shall be provided to monitor the fuel level of either tank from a single fuel gage; or an equalizing pump shall be used to maintain the same fuel level in both tanks.

3.4.3.3 FUEL AND WATER SEPARATOR

The manufacturer’s standard or optional fuel filter shall be provided. A fuel and water separator shall also be furnished for diesel engines. The separator shall include water coalescent, heater, and a drain valve. A combination filter/separator unit may be provided. Separators heated by engine coolant and cast into the engine block do not need a separate heating element.

3.4.4 EXHAUST SYSTEM

The exhaust system shall conform to Federal Motor Carrier Safety Regulation 393.83.

3.4.5 TRANSMISSION

The type of transmission required for each item is specified in AutoChoice.

The net torque capacity and the net power rating of the transmission shall meet or exceed the output ratings of the engine in all gears.

All transmissions shall be provided with a power takeoff provision to include gear and opening. All transmissions must be filled with the transmission manufacturer’s required synthetic fluid to provide maximum warranty coverage.

3.4.5.1 AUTOMATIC TRANSMISSION

Automatic transmissions shall include a hydraulic torque converter. The transmission shall be provided with a live power takeoff provision. The net torque capacity and the net power rating of the transmission shall meet or exceed the output ratings of the engine in all gears. Allison transmissions must be filled with Allison TransSynd or other TES295 approved synthetic fluid to provide maximum warranty coverage and extended drain intervals.

3.4.5.2 CLUTCH

The clutch shall have a torque capacity exceeding the maximum delivered engine torque. The clutch lining shall be asbestos free. The clutch shall be equipped with spring dampening and a greaseable bearing. An extension hose or tube shall be installed to make it easier to grease/lubricate the release bearing.

3.4.5.3 TRANSFER CASE

A two-speed transfer case shall be provided on 4x4 and 6x6 vehicles. Unless the transfer case is equipped with devices which compensate for differential torque and speeds between front and rear axles, the transfer case shall provide for driver selection of either four-wheel or six-wheel drive. Inter-axle compensating devices shall provide for positive transfer of power to all driving axles. The speedometer shall read accurate vehicle speed with the transfer case speed selector in high and in low range. An overlay on the speedometer face may be utilized to indicate accurate speed in low range.

3.4.6 DRIVELINE COMPONENTS

Driveline components shall be rated to transmit the maximum delivered torque of the engine, as developed through the maximum gear train reduction. Components shall be rated no less than the GCWR required for each item. Drivelines shall be balanced and free of vibration. The drive shaft for front mounted winches shall have an angle not greater than 16 degrees from the longitudinal plane.

3.4.7 FRAME

Frame rails shall not project beyond the rear end of the body. The transmission shall be provided with a live power takeoff provision. The net torque capacity and the net power rating of the transmission shall meet or exceed the output ratings of the engine in all gears.

3.4.8 SUSPENSION

The vehicle shall be equipped with a suspension system with components having a rated capacity at least equal to the load imposed on each member, measured at the ground, with the vehicle loaded to specified GVW. When suspension is rated at the spring pads, un-sprung weight shall be deducted.

Hydraulic double-acting shock absorbers shall be provided on the front and rear axle(s). Only those suspensions that cannot by design have shock absorbers added can omit this requirement.

For dump trucks and stake trucks with tandem rear axles the suspension system must be a walking beam type system with rubber elastomeric pivot points. Brands and models acceptable include Hendrickson HN VariRate, Ultimax, Haulmaax, RS Series Rubber Walking Beam, Mack mRide, and Daimler TuffTrac.

3.4.9 AXLES

Axle ratings shall be at least equal to the load imposed on each axle, measured at the ground, with the vehicle loaded to specified GVW. The wheel bearings and axle spindles shall be oil lubricated or of a unitized, lifetime sealed no-maintenance design, except on front drive axles. For oil filled hubs, a window shall be provided for visual determination of oil level and provisions for venting or withstanding internal pressure buildup and for replenishing the oil supply shall be provided.

3.4.9.1 REAR BOGIE

The bogie shall be provided with means permitting differential action between the two axles, and a manually or automatically controlled lockout assuring equal power to each rear axle. The manual lockout control used shall be located in the truck cab.

3.4.9.2 TRACTION CONTROL

When specified as a minimum requirement or when option ATC is selected the vehicle’s brake system must be used to control a powered spinning wheel and transfer power to the opposite side. A mechanical locking differential cannot be provided in place of electronic controlled traction system.

3.4.10 WHEELS, RIMS AND TIRES

Unless wide base tires are specified, the vehicle shall be equipped with single front and dual rear wheels. Rims and tire ratings shall conform to Tire and Rim Association.

3.4.10.1 TIRES

The tire type required for each vehicle is listed in the Standard Items Minimums. Optional tires are available under “Options” for each Standard Item. Tires shall be of the tubeless type with a rated capacity at least equal to the load imposed on each tire, measured at each wheel, at the ground, with the vehicle loaded to specified GVW. Tires shall conform to the Tire and Rim Association recommendations. Under no circumstance shall the vehicle maximum governed speed exceed the speed rating of any of the furnished tires. Tires are defined as low profile when the side profile aspect ratio is 60, 65, or 70 percent. All front tires shall be ribbed. Tires shall be matched to provide best possible performance for the prescribed application.

a. 4x2 and 6x4 Dump trucks shall have an On-Off Highway, open lug design drive tire such as the Goodyear G282 MSD with a ribbed steering tire such as the G287 MSA.

b. 4x2 and 6x4 Cab and Chassis, Stake, Dry Van, Refrigerated Van, Maintenance Body, and Forestry Body trucks shall have a Regional/Urban tire such as the Goodyear RHD II G137 on the drive axle(s) with a ribbed steering tire such as the G395 LHS.

C. 4x4 and 6x6 Standard Items shall have an On-Off Highway, open lug design drive tire such as the Goodyear G282 MSD with a steer tire rated as an all position/steer tire such as the G288 MSA.

d. All tractors that do not have a powered front axle shall be equipped with SmartWay verified tires.

e. 4x2 and 6x4 tractors with dual rear tires shall have a LongHaul Drive position tire such as the Goodyear G572 LHD FuelMax and a steer tire with a ribbed design for increased fuel economy and mileage such as the Goodyear G399 LHS FuelMax.

f. Tractors with single drive tires shall have a 445/50R22.5 super single such as the Goodyear G392 SSD with self sealing feature on all rear axle ends and a ribbed front tire with enhanced fuel and mileage such as the Goodyear G399 LHS FuelMax.

3.4.10.2 TIRE CHAIN CLEARANCE

Tire chain clearance in accordance with SAE J683 shall be provided. Allowance for spring deflection shall be included.

3.4.11 BRAKES

Brakes shall conform to Federal Motor Carrier Safety Regulations. The brake system type required is specified in “Minimums” under each Standard Item.

3.4.11.1 SERVICE BRAKES

When an air brake system is furnished the following shall be included:

(a) Air compressor, unloader-head type, engine driven

(b) Air dryer

(c) Air storage reservoir(s), each tank equipped with drain, and with safety and check valves between the compressor and the last reservoir tank.

(d) Foot control, suspended or treadle type

(e) Air control valves

(f) Air pressure gage, visible to the driver

(g) Low air pressure warning, visible and audible

(h) Service brake stop lamp switch

(i) Automatic moisture ejector on primary air (wet tank) storage reservoirs with heated discharge port and a quarter turn manual value.

(j) Automatic slack adjusters on cam type brakes or internal self-adjusting brakes on wedge and disc type brakes on all axles

3.4.11.1.1 AIR DRYER

A Bendix AD-IP model or equal air dryer with a replaceable spin on/off desiccant cartridge shall be installed in the air brake system. The dryer shall have the capability of removing not less than 95 percent of the moisture in the air being dried. The dryer shall have a pre-cooler and a filter to screen out oil and solid contaminants. The dryer shall have an automatic self-cleaning cycle and a thermostatically controlled heater to prevent icing of the purge valve.

3.4.11.2 TRAILER BRAKE CONTROL SYSTEM

Trailer brake control…