QMAE-EV-190002-D_Attachment_6_-_Federal_Standards.pdf

Combined Fed Std 794AM Fed Std 807AB January 9, 2020 Superseding Fed Std 794AL Fed Std 807AA January 9, 2019

FEDERAL STANDARD

TRUCKS AND TRUCK TRACTORS: Medium and Heavy Commercial 19,000 pounds and greater Gross Vehicle Weight Rating

FSC CLASS 2320

Fed Std 794AM/Fed Std 807AB/January 9, 2020

1. SCOPE AND CLASSIFICATION

1.1 PURPOSE

This Standard covers new commercially produced classes 5, 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. This Standard is applicable to GSA contract year 2020.

1.2 APPLICATION

This 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. 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, 8 Carriers 5, 6, 7, 8 Dry Van 6, 7, 8 Dump 6, 7, 8 Forestry 6 Maintenance Body 6 and 7 Refrigerated Van 6, 7, 8 Stakes 6, 7, 8 Truck Tractors 6, 7, 8 Wreckers 5, 6, 7, 8

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 5 6 7 8

(LBS) 16,001 - 19,500 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 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 these codes are specified.

2.0 APPLICABLE DOCUMENTS

2.1 GENERAL SERVICES ADMINISTRATION STANDARD REQUIREMENTS DOCUMENTS

The complete sets of requirements for products required under this Standard are 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 the 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 Standard 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.

2.1.1.1 COMMERCIAL ITEM DESCRIPTIONS

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

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

2.1.1.2 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.

2.1.1.3 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.

2.1.1.4 FEDERAL STANDARDS

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

2.1.1.5 MILITARY STANDARDS

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.

2.1.2 OTHER GOVERNMENT DOCUMENTS, DRAWINGS, AND PUBLICATIONS

The following other Government Standards, 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/

2.1.2.1 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/

2.1.2.2 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/ Regulations for Greenhouse Gas Emissions from Commercial Trucks & Buses

2.1.2.3 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 OTHER PUBLICATIONS

The following documents form a part of this Standard 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.

2.2.1 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

2.2.2 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

2.2.3 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 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 J706 Ratings of Winches J844 Nonmetallic Air Brake System Tubing (DOD adopted) J994 Alarm- Backup- Electric J959 Lifting Crane, Wire-Rope Strength Factors J1067 Seven-Conductor Jacketed Cable for Truck-Trailer Connections J1273 Recommended Practices for Hydraulic Hose Assemblies J2188 Truck Ability Prediction Procedure (DOD adopted) J2394 Seven Conductor Cable for ABS Power – Truck and Bus J2512 Towing Equipment Ratings and Practices

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

2.2.4 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

2.2.5 THE MAINTENANCE COUNCIL (TMC).

Recommended Maintenance Practices Manual RP 105C Battery Cable Assemblies RP 111C Circuit Protections RP 114B Harness Protection RP 120B Wiring Systems Identification RP 138A Auxiliary forward lighting.

RP 160 Wiring and circuit protection guidelines for 12-volt DC to 120-volt AC in-cab inverter systems RP 163 Power inverter selection recommendations RP 403A Placement of Safety Equipment RP 404B Truck and Tractor Access System RP 417A Supporting pneumatic electrical lines between cab and trailer.

RP 710A Overhead door selection RP 711 12 year life swing - type freight van, trailer doors RP 723A 12-Year life North American laminated hardwood flooring for dry freight van trailers RP 751 Safety Chains and Attachments RP 753 Guidelines for liftgate decals

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 this Standard supersedes applicable state and federal safety 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 DESCRIPTION DEFINITION

AMP Ampere Unit of electric current.

BA Bumper-to-Axle Horizontal dimension from the foremost point of the front bumper to the center line of the front axle

BBC Front Bumper-to-Back of Cab Horizontal dimension from the foremost point of the front bumper to the rear-most surface of the cab

BH Boom Height Vertical distance from the ground to the top-most point of the wire rope sheave pulley (wrecker fully loaded with fuel, two 175lb passengers, normal recovery accessories, jacks retracted, recommended tire pressure)

BL Bed Length Measure of bed from front leading edge or rear of headboard to rear trailing edge not including any other attachments.

CA Cab-to-Axle Horizontal dimension from the rear-most surface of the cab to the center line mid-way between the axles on a tandem-rear-axle truck chassis.

CAP Capacity Maximum volume or measure of ability.

CYL Cylinders Reference engine piston count.

CL Crane Load Distance from center of crane base to load.

FT Foot or Feet USA measure of distance.

GAS Gasoline Reference to a gasoline fuel system.

GAWR Gross Axle Weight Rating The load-carrying capacity of a single axle system, as measured at the tire-ground interface

GCWR Gross Combination Weight Rating The maximum allowable combined mass of a towing road vehicle, passengers and cargo in the tow vehicle, plus the mass of the trailer and cargo in the trailer.

GVWR Gross Vehicle Weight Rating The maximum operating weight of a vehicle as specified by the manufacturer including the vehicle’s chassis, body, engine, engine fluids, fuel, accessories, driver, passengers and cargo but excluding that of any trailers.

HYD Hydraulic Reference hydraulic systems.

HP Horsepower Reference engine manufacturer’s advertised horsepower.

IN Inches USA measure of distance.

L Liters Metric unit of capacity.

LP Lift Point Prescribed location acceptable for attaching a lifting device.

LB and LBS Pound and Pounds USA unit of measuring weight.

MAX Maximum Upper limit

MIN Minimum Lower limit

MPG Miles per gallon Road miles traveled for one gallon of fuel consumed.

N/A Not applicable or not available Reference to Not applicable or not available.

OEM Original Equipment Manufacturer A company that makes a part or subsystem that is used in another company’s end product.

PTO Power takeoff opening Port in transmission used to power auxiliary equipment.

RBM Resisting bending moment Result of multiplying the frame beam yield strength and section modulus.

WB Wheelbase Distance as measured between the centerline of the front axle and the centerline of the rear axle for two axle vehicles and to the center of the rear tandem on three axle vehicles.

W/ and W/O With and without Reference with and without.

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 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 aluminum and stainless steel, shall be treated and painted in accordance with MIL-HDBK-1223. The manufacturer’s standard treatment and painting for cab and chassis is acceptable unless otherwise specified. The standard exterior color for the cab and body shall be the brightest white available from the manufacturer’s colors.

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 PRIME MOVER 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.

Towing devices can be a removable type using pin through receiver or threaded shaft for mounting and stored elsewhere in the truck until needed. Bolt on devices will not be considered as removable.

3.1.1.5 WHEEL SPLASH AND STONE THROW PROTECTION

Stakes, dumps, vans, wreckers and carriers 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. As an alternate method of attaching the mud flaps, tabs or clips shall be furnished for quick release. 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 RESERVED

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.

(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 22-in and not more than 54-in, 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 shall be 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 COMPONENTS FOR TRUCK BODIES AND ACCESSORY EQUIPMENT

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

3.1.2.1 BRAKE LIGHTS

All brake, turn, and taillight assemblies shall be mounted so the bottom most edge of the lens is at least 20 in from level ground when the vehicle engine is running and the chassis is at normal operating curb weight and height. There shall be no obstruction covering the lens of any assembly except when a protective mesh is used over the lamp assembly on the rear and sides of the truck.

The requirements of FMVSS 108 must be maintained when lens is covered by protective mesh.

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 in this requirement.

2. Electric motor driven pumps can only be used to power hydraulic liftgates, unless otherwise specified.

3. Engine crankshaft driven front power take off, integral frame extensions and OEM approved and furnished chassis for front PTO application shall be used when pump output requirements exceed the transmission drive capability or the pump size exceeds the space available next to transmission and beside the frame rail.

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-in 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.

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

1. Hydraulic pressure hoses shall be rated to not less than SAE 100 (two wires). Return hoses shall be rated to SAE 100 (one wire) or can be less so long as the maximum return pressure is within safe margin of maximum pressure rating.

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.

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 a mechanism to prevent hydraulic shock if the implement strikes an obstruction while the vehicle is in operation. The system shall incorporate a crossover control relief valve to prevent the shock from damaging the hydraulic cylinder.

5. Hydraulic hose fittings shall be permanently attached (crimped). 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.

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.

E. Fluid filtration

A return line hydraulic filter shall be furnished. The filter shall be furnished with a pressure differential type service gauge 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 or plastic hydraulic reservoir shall be furnished and sized such that the reservoir working volume is a minimum of 125% of the maximum hydraulic flow rate and no greater than 40 gallons so long as maximum temperature is not exceeded under designed operating conditions. 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 an air filtration type breather or combination breather cap with not greater than 40-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 30 mesh or tighter, maximum 595 micron fill strainer.

5. Reservoir tanks with a top return shall incorporate a return tube that discharges return oil below the surface of the reservoir oil.

6. Reservoir tanks shall be located on top of or between the frame rails behind the cab on dumps and tractors. This location can be changed to the side of frame when an analysis of the standard equipment and options required for any one build creates a situation where the frame length will be shorter if a side of frame mounted tank is used in place of one mounted on top of the frame. Stake trucks shall have the tank mounted on the side of or between the frame rails.

7. A means shall be provided to determine if the reservoir is at the proper level of fluid. A sight glass or dip stick measure shall be in easy view/reach of the operator for inspection.

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 or permanent adhesive backed sticker 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 or when a single line wet line kit option is used, a gear type pump can be provided when no other hydraulic equipment is added which requires hydraulic power from the primary pump. For dump trucks of 10 yards and greater or when two line or more 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 2,000 psi. The maximum governed engine speed while the hoist PTO is active must not allow the pump speed to exceed the pump manufacturer’s limit. For dump hoist applications where a front engine driven pump is furnished and 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. For transmission mounted PTO and pump systems the pump shall be a variable displacement load sensing piston pump and meet the GPM requirements of all installed consumers on the system operating at full speed. The variable displacement pump(s) 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. When additional hydraulic circuits are incorporated into the system such as for plows, spreaders, and wet line kits, the hoist may return to its resting down position in 50 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 or nitride hardened. The hoist shall lift the body to a minimum dumping angle of 45 to 50 degrees from the top of the truck chassis frame. The telescopic hoist shall be capable of lowering the raised body by gravity when the pump is disabled. A control lever shall be provided in easy reach of the operator that allows controlled rise, hold, and lowering the dump hoist. At a minimum the control must also provide a feathering function to the lowering operation.

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

L. 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. Hoses shall not be allowed to droop or to be entangled with other hoses or lines. Supports 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. Hose routing that subjects the hose to damage from other components

c. Hose routing closer to the ground than the bottom of the fuel tank

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

M. Operational Test

1. The operational test shall include the maximum requirements (height, extension, speed, etc.)

of the driven devices under no-load conditions.

2. The hydraulic system and hydraulically driven components shall be operated and checked for leaks and proper operation.

3. 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 90 db 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 200 lbs. 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 200 lbs. 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. The above shall not be interpreted to mean that the use of used or rebuilt products is allowed under this Standard. 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 (65 mph for 4x4 and 6x6) unless the tire vocation and axle/weight applications require a tire that must be speed reduced, and no more than 75 mph. Under no circumstance shall the vehicle maximum governed speed exceed the speed rating of any furnished tires.

3.4 CHASSIS COMPONENTS

3.4.1 ENGINE

The engine minimum liter size, horsepower, and torque required as standard equipment are stated for each Standard Item in Autochoice. A larger engine than required can be provided at the vendor’s discretion.

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 but they can be used in conjunction with another supporting device to secure the hose so long as it does not provide vertical support.

Wire ties shall be UV resistant 6/6 heat stabilized with a tensile strength of at least 50 lbs and as appropriate for the application. Lesser tensile strength ties can only be used for bundling.

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.

3.4.1.6 RESERVED

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 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.

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. The positive jump post shall be furnished with a protective rubber or plastic type covers that are tethered to prevent loss. In place of a negative jump post the junction point for the negative battery cable and the chassis ground point can be used so long as that point can be easily reached with standard jumper cables. Jump posts are not required on electric 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 lighting shall have internal voltage regulation.

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

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

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

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

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

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

j. 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).

k. 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.

l. 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.

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

n. 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.

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

p. All dumps shall have two sets of LED stop/tail/turn and reverse lights with one set at rear of the chassis and the other set in each of rear posts of dump body. The lamps in each of the rear posts of the dump body shall be 6-in oval with one red or clear with red LED elements for the stop/tail/turn function and the other clear with white LED elements for the reverse light function. When the rear post of the dump body does not have enough room for three 6-in oval lamps when optional amber flashing warning lamps are required, the 6-in red stop/tail/turn can also incorporate a clear center section with white LED elements for the reverse lamp function.

3.4.2.4 TURN SIGNALS

Temporary mounting for rear signal units shall be provided on cab/chassis items.

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 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.

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. Diesel fuel tanks shall be made from aluminum with a natural or polished finish. For all applications, care shall be taken to provide a combination of fuel tank volumes that provide the shortest possible chassis while still meeting the required standard or optional fuel capacities.

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. For dump trucks, the fuel filter and the fuel water separator shall be protected from impact and road debris or located either in the engine compartment or inside the frame rails.

3.4.4 EXHAUST SYSTEM

The exhaust system shall conform to Federal Motor Carrier Safety Regulation 393.83. The standard routing of the exhaust system, either vertical or horizontal, is specified in Autochoice.

3.4.5 TRANSMISSION

The type of transmission required for each Standard 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 except if otherwise specified.

All cab and chassis items furnished with a transmission that includes a PTO opening on the transmission shall be furnished with a PTO engagement control switch located on the dash. The switch can be either air over hydraulic or electric over hydraulic depending on the transmission furnished as standard or optional.

All transmissions must be filled with the transmission manufacturer’s required synthetic fluid to provide maximum warranty coverage. Manual transmissions are those with straight cut or helical cut gears that remain in constant mesh and require a device (clutch) to disengage the input power flow from the gear cluster in order to change forward output ratios. The gear ratio changes are accomplished by the driver operating a lever which changes the set of gears that provide the power flow throughput. An automated manual transmission is one that uses a constant mesh gear system and clutch that is controlled and gear ratios changed by a computer controlling servos. A dual clutch transmission uses separate clutches (and separate gear shafts) for the even-numbered and the odd-numbered gears. In this way, the next expected gear is pre-selected. When a shift is required, the controller disengages the clutch currently in-use while simultaneously engaging the clutch not currently in-use, thus making a smooth and fast shift.

When a towing package is specified by option the transmission may need to be upgraded to handle the load of the truck and trailer combination. The total load shall be calculated by using the empty weight of the truck at operating curb weight with a full tank of fuel and the added total weight rating of the trailer hitch. When the truck and trailer hitch combination will exceed the capacity of the standard equipment transmission a collision shall be set in AutoChoice. This collision shall be a “requires” statement for a transmission or creating an “or” statement when a list of transmissions can be selected from to handle the loads that will be imposed.

3.4.5.1 DRY PLATE CLUTCH

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

3.4.5.2 AUTOMATIC TRANSMISSION

An automatic transmission uses a fluid coupling (torque converter) with gear changes accomplished by locking and unlocking a system of planetary gears. The transmission shall be provided with a live power takeoff provision except when the transmission required does not offer a PTO 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 shall be filled with Allison TransSynd or other TES295 approved synthetic fluid to provide maximum warranty coverage and extended drain intervals. The Allison transmission shall be programmed for a performance oriented shifting to allow the engine to reach maximum RPM under heavy load conditions in all gear selections. The programming shall also provide for fairly aggressive downshifting from high speeds to help slow the vehicle with or without brake application. The programming shall also include a learn function which modifies the shifting based on driver use.

3.4.5.3 TRANSFER CASE

A 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

Specified frame resistance bending moment (RBM) is calculated by using the section modulus number and multiplying it by the known yield strength. The minimum required RBM for each Standard Item is listed in AutoChoice under Minimums.

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, stake, wrecker, and carrier 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, RT Series, Ultimax, Haulmaax, RS Series Rubber Walking Beam, Mack mRide, Chalmers 800 Series, and Daimler TuffTrac. When shocks must be positioned behind the rear most axle on dump trucks and they are not required by the suspension system, they should be eliminated to reduce the body overhang past the end of the chassis.

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 for non-powered 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. Powered front axles can be have serviceable grease packed hub bearings when oil filled or no-maintenance types are not available.

3.4.9.1 REAR BOGIE

The bogie shall be provided with a means of permitting differential action between the two axles. The inter-axle lock function shall be controlled by the driver through a dash mounted switch. Each axle of the tandem shall include a mechanical differential action lockout that is controlled by the driver through a dash mounted switch.

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 50, 55, 60, 65, 70, 75, and 80 percent. A tire is low profile when the aspect ratio of the standard tire for an application is greater than what is offered under the profiles listed.