T68-60-01 Tand 15Ft Dump~2.docx

Specification No T68-60-01

Specification No. T68-60-01 Specifications and Questionnaire for a Super Tandem Axle Dump Truck with 15’ Body State of Illinois Department of Transportation Bureau of Business Services Specifications and Questionnaire for a Super Tandem Axle Dump Truck W/15’ Body with 240 Gallon Pre-wet System October 2022 This specification and questionnaire describes a Tandem Axle Dump Truck with 15-foot body for use in Department of Transportation highway maintenance operations. These vehicles may be required to perform in adverse and emergency conditions. Compliance with the specifications is essential for the operation of this equipment in those conditions.

It is the responsibility of each bidder to complete and return this questionnaire with the bid.

Bidders are advised to carefully read these specifications.

Proposed with this Bid:

Note: If the equipment proposed exceeds the minimums called for in the specification please do not mark NO. Mark Yes and explain with a short comment on how it exceeds.

I. Chassis:

Capacity:

G.A.W.R. - Front - 18,000 lbs. minimum.

G.A.W.R. - Rear - 46,000 lbs. minimum.

Tandem axle chassis rated G.V.W.R.:

Cab-to-Center of Rear Axle Dimension (C.T.):

As required for body and optional equipment mounting.

Frame:

Galvanized straight channel with a minimum section modulus of approximately 25.

Resistance to Bending Moment - 3,000,000 minimum for entire length of frame.

Reinforcement - Shall extend forward through both front spring hangers to front snowplow hitch mounting points.

Note: Wrapped or channel reinforced rails are not acceptable or compliant with these specifications.

Frames shall include integral front frame extensions for front engine PTO. Bolt on or fabricated extensions will not be acceptable.

The frame shall have holes punched for a frame reinforcement bar (to be installed by others). Mounting holes shall be punched forward of the transmission and to the rear of the engine.

Complies: |_| Yes |_| No

The Frame Reinforcement member shall consist of an additional crossmember constructed of heavy-duty, laminated steel plate, similar to that depicted in the illustration.

The reinforcement bar shall be provided and installed by the Body Company, bolted to the frame in holes provided by the chassis manufacturer.

Complies: |_| Yes |_| No The design, and actual location of this additional crossmember will be finalized prior to chassis construction following consultation with the chassis manufacturer, body company and the Department of Transportation. Changes in engine, exhaust, etc. can result in the relocation and design alteration of this component.

Complies: |_| Yes |_| No Front Axle & Front Suspension:

Front Axle:

Set forward, Single I-beam type, rated at 18,000 lbs. minimum and shall be wide tract type.

Front Suspension:

The front suspension shall be taper leaf type, multi-leaf or two-stage type with a total capacity at ground of 18,000 lbs. minimum including 2,000 lb. overload auxiliary front springs and shock absorbers.

Shocks: |_| Yes |_| No

Note: Trucks covered by this specification will be subjected to higher-than-normal front axle loading when equipped with front-mounted snowplows. Equipment weighing 2,500 pounds may be carried forward of the front axle during snow removal operations. The high-capacity axle and suspension are required to offset the effects of this additional load and to reduce the number of front spring and axle failures incurred in this type of operation. Auxiliary front rubber springs shall be included with the front springs. The front axle and suspension capacities must be met if the proposed trucks are to be considered.

Brakes:

The air brake system shall be manufacturer’s standard heavy duty, full air style, with two painted aluminum reserve tanks. One tank shall be equipped with an easily accessible remote air connection. Connection shall consist of female air coupler on stationary mount with protective cap (see reference photo). All brake dust covers shall be included. Front shall be a minimum 16.5 X 6 - 24 sq. inch brake chambers, rear shall be 16.5 X 7 - 30/30 sq. inch brake chambers or equal. The effective lining area as required for GVWR and GAWR ratings.

Note: Brake chambers on tandem axle trucks shall be positioned to avoid contact with push style asphalt pavers.

Complies: |_| Yes |_| No

Air Coupler

Brake Accessories:

Heated automatic reservoir drain valve. Bendix DV-2, Meritor or equivalent. Drain valve shall be level with bottom of air tank.

Component:

Automatic slack adjusters, shall be stroke sensing style, front and rear shall be Haldex/Eaton, Gunite, Meritor or equivalent.

Component:

Air Dryer - Bendix AD-IP, Meritor or equivalent with heater.

Air Horn:

Manufacturer’s standard operator-controlled air horn(s) with snow shields (only required if exterior mounted).

Complies: |_| Yes |_| No Note: Air horn mounting shall not interfere with the light bar mounting by the body company. Under hood mounting is acceptable.

Air Compressor:

The compressor for the air brake system shall provide a minimum of 18.7 CFM capacity or as required by engine manufacturer.

Emergency Brake:

Type - Air operated with cab control emergency air supply valve and remote air reservoir. Audible alarm shall sound if driver’s door opens and brake is not applied.

Complies: |_| Yes |_| No Trailer Brakes (Air & Electric):

An air brake trailer control package shall be provided. It shall include control lever and air lines mounted in a block or at the pintle plate at the rear of the frame. Both non-abs and abs electrical plugs shall be included.

Complies: |_| Yes |_| No

Glad hands with a 6” flexible mount or equal shall be installed at the rear pintle plate.

Complies: |_| Yes |_| No An electric brake controller and wiring shall be provided by the chassis manufacturer for use in connecting to trailers with electric brakes.

Complies: |_| Yes |_| No The electric brake rear socket shall be installed by the body company. The location shall be confirmed at the completed truck pilot inspection.

Complies: |_| Yes |_| No The wiring for the trailer plug shall be as described under the heading “Special Trailer Harness” (page # 19) later in this specification.

Complies: |_| Yes |_| No Power Steering:

Type - Manufacturer's standard dual assembly or severe-duty with assist is required.

Complies: |_| Yes |_| No Steering Wheel:

Maximum diameter 18" with tilt and telescopic adjustment features.

Exhaust System:

Horizontal muffler (or as needed to meet emissions) with supported vertical exhaust pipe and heat guard. It shall not be higher than the light bar.

Complies: |_| Yes |_| No Electrical System:

Type - 12-volt, negative ground.

Complies: |_| Yes |_| No Alternator:

Type -Heavy-duty, brushless pad mounted Ampere Rating - 180 ampere Minimum.

Batteries:

The truck chassis manufacturer shall provide three (3) Premium AGM batteries, new first run quality. They shall be a long life, maintenance-free, SAE Cold Cranking Ampere Rating of 2400 minimum. The batteries shall include external jump studs and must meet or exceed engine manufacturer's requirements at -17C. (0o F).

Hybrid Solar and AC Current Battery Management System:

A complete solar and AC current battery maintaining system hardwired to chassis batteries. The system shall include an external compact weatherproof solar panel(s), compact control module (MPPT) with charge indicator and required wiring. The solar panel output shall be sized to meet peak battery maintenance. AC plug shall be mounted next to block heater plug under driver’s door. Control module(s) mounting location shall be discussed with IDOT prior to build. Minimum 5-year product warranty.

Component:

Complies: |_| Yes |_| No

Battery Disconnect or Auto-Shutdown Feature:

An interior manual disconnect located at or near secondary fuse center or ignition activated shutdown feature shall disconnect the trucks battery source during a jumpstart.

Component:

Complies: |_| Yes |_| No Electrical Circuit Protection:

Circuit breakers - Manual reset breakers should be used in place of fuses whenever possible.

Rating - As required for adequate electrical protection. Shall not reset until overload has been corrected.

Complies: |_| Yes |_| No Standard Lights:

Headlights with High/Low Beams:

Type – Halogen Sealed beam or LED, 2 or 4 elements. The lights shall be activated at low voltage with the ignition with an operator controlled override.

Location - Standard production location.

Lens color - Clear.

Control - Combination light control switch with floor- or turn-signal mounted dimmer control.

Complies: |_| Yes |_| No LED-Combination Tail/Stop and Rear Signal:

Type - Dual combination Class A, LED, sealed, shock mounted, Truck-Lite, Grote or equivalent.

Location - Rear of truck chassis or dump body sub-frame.

Lens color - Red.

Taillight control - Combination light control switch.

Brake light control - Brake control.

Turn signal control - Turn signal control switch and 4-way hazard warning switch.

Complies: |_| Yes |_| No LED Front Turn Signal and Parking Lights:

Location - Front fenders.

Lens color - Front - Amber.

Parking light control - Combination light control switch.

Turn signal control - Turn signal control switch and 4-way hazard warning switch.

Complies: |_| Yes |_| No LED-Backup Light:

Type - Dual, oval 2” x 6” single-face, sealed, shock mounted, High Intensity LED.

Location - In the dump body rear corner braces.

Lens color - Clear or white.

Control - Transmission selector control.

Complies: |_| Yes |_| No LED License Plate Lamp:

Type - Sealed, Truck-Lite 15 Series, Grote or equivalent.

Lens color - Clear.

Control - Combination light control switch.

Complies: |_| Yes |_| No LED-Cab Clearance Lights:

Location - Outer front edge of cab top.

Lens color - Amber.

Control - Combination light control switch.

Complies: |_| Yes |_| No

LED-Rear Identification Lights (3-Bar):

Type - Three, single-face, reflectorized, sealed, and shock mounted - Truck-Lite #10050R with #10702 closed back grommet, Grote SuperNova or equivalent.

Location - Rear of dump body.

Lens color - Red.

Control - Combination light control switch.

Complies: |_| Yes |_| No LED-Body Clearance Lights:

Type - Single-face, reflectorized, sealed, and shock mounted Truck-Lite #10050R with #10702 closed back grommet, Grote SuperNova or equivalent.

Location - As required.

Complies: |_| Yes |_| No LED Step Lights:

Type - Single-face, LED, sealed, and shock mounted with grommet approximately 2-1/2” in size.

Location – Front of Driver and Passenger entry steps facing the rear or at an angle to focus light on steps.

Control – Dash mounted switch left side of dash.

Complies: |_| Yes |_| No Reflectors:

As required by Illinois State law.

Complies: |_| Yes |_| No 4-Way and Signal Flasher:

Type - Heavy-duty, and solid state, minimum capacity, as required to continuously operate all turn signal lamps simultaneously.

Complies: |_| Yes |_| No Lighting Safety Pre-check:

The standard chassis lights shall be programmed to alternate in a sequence so that a single operator can visually inspect.

Complies: |_| Yes |_| No |_| Not available Engine Accessories:

Air Filter - Dry type – Dual element or element with pre cleaner, with dash mounted in cab control to provide air flow from outside the truck or under the hood as selected by the operator. The control shall be labeled for Winter or Summer locations and shall include an in-dash air cleaner restriction indicator.

Oil Filter - Removable cartridge mounted on the engine block.

Complies: |_| Yes |_| No

A pre-engine combination fuel moisture separator and fuel heater. Parker/Racor, Davco or equivalent fuel heater, filter/water separator with preheat.

In-Block Type Engine Heater – minimum 110 volt with receptacle mounted under the driver’s door or other suitable location approved by the Department of Transportation.

Emissions Catalyst Heater/Cooler (if available) – Trucks need to be capable of operating during extreme weather conditions where ambient temperatures may be above 100 deg. F or below -10 deg. F.

Complies: |_| Yes |_| No |_| Not Required Non-Corrosive Oil Pan – A heavy duty oil pan or an oil pan that is designed for use in corrosive environments where road salt is present shall be provided. It can be Factory or Dealer installed.

Complies: |_| Yes |_| No Component:

Engine:

To maintain standardization, continuity and fleet integrity, Cummins current production, advertised 12 liter electronically controlled, turbo-charged, charge air cooled diesel engine. Engines considered must provide a minimum 380 horsepower with 1,450-foot pounds of torque at an RPM within the governed operating range of the engine. The engine(s) considered must include a factory installed front engine PTO adaptor plate.

Component:

Complies: |_| Yes |_| No

Cooling Systems:

Capacity - As needed for continuous low-gear operation with loads of rated capacity. Radiator must be front-to-back style with minimum 1,200 sq. in. of surface area.

Complies: |_| Yes |_| No Note: If the driveshaft for the PTO is installed through the radiator a containment ring shall be integrated into the design to prevent excessive damage in the event of a drive shaft failure. Grease zerks shall be accessible when driveshaft is installed.

Complies: |_| Yes |_| No Coolant shall be “long-life” type anti-freeze requiring minimal maintenance.

Complies: |_| Yes |_| No The cooling fan shall be a rear tethered, air controlled, ON/OFF style, activated by coolant temperature with a manual, operator controlled over-ride. Horton Drivemaster, Borg Warner or equivalent.

Component:

Cold Weather Starting Aid – Grid type heater or equivalent with electric cab control, with ECU or ECM and shall not require the use of starting fluid.

Transmission:

Shall be an Allison MD 4500 RDS or equivalent automatic. The operating ranges shall include - 1, 2, 3, 4, 5, neutral, and reverse. The truck shall be equipped with an external transmission fluid cooler (separate from the radiator). The transmission controller (ECM) shall be interior cab mounted or mounted under the hood on firewall in an area that is protected from the weather. If truck is equipped with Tow Plow option, the programming shall allow for gear hold in Performance based shifting.

Note: All transmission default settings shall be reviewed with IDOT representatives and the successful bidder prior to ordering chassis.

Component:

The transmission shall include vehicle interface module with access provided to a technician through the shift control.

Complies: |_| Yes |_| No Shift and Indicator mounting shall be located on the dash or steering column. Floor mountings will not be acceptable.

Selector:

Transmission range selector with lighted position indicator must also provide mode selection and diagnostic features. Dash or selector indication is acceptable. Indicator must clearly indicate all ranges as listed above.

Complies: |_| Yes |_| No Please indicate which selectors are available by Manufacturer.

Note: All transmission selectors shall be reviewed with IDOT representatives and the successful bidder prior to ordering chassis.

Transmission Oil Filter:

Transmission oil filter shall be an internal, replaceable, element style. The fill tube shall be mounted on the passenger side of the transmission.

Complies: |_| Yes |_| No Tandem Rear Axle & Rear Suspension:

Single speed with operator controlled differential lock, power divider lock (IAD) and a capacity at ground of 46,000 lbs. minimum.

Axle Ratio - Shall be of sufficient ratio to acquire speeds of 70 MPH, optimum plowing speeds of 35-45 MPH under load. The minimum driveline rating with this combination shall be SPL long life type or equivalent. Tow Plow option shall be considered when evaluating ratios.

Note: IDOT is aware tires and Tow Plow option can affect overall top speed.

Note: Axle ratio and drive line rating will be discussed with the successful bidder prior to production. Only manufacturer’s standard production ratios will be considered.

Rear Suspension:

Hendrickson HMX EX-460 rear suspension with a rating of 46,000 lbs. minimum and shall include shock absorbers.

Fuel Tank(s):

The tank(s) shall be aluminum or stainless steel.

The tank(s) shall be safety step type, located under the cab skirts providing 100 gallons total capacity. A minimum of 70 gallons is required if tank size is reduced for clear back of cab for the mounting of optional attachments.

Note: Tank(s) providing lesser capacity will be allowed if necessary for the body installer to locate optional plows and scrapers after review with the Department of Transportation representatives.

The tank steps shall be constructed with manufacturer's standard open-grated, anti-skid material. The steps and straps shall be stainless steel, aluminum, or powder coated steel.

Complies: |_| Yes |_| No Each tank shall be lettered with "ULTRA LOW SULFUR DIESEL FUEL ONLY". Letters to be a minimum of 1 inch high, block type. . If truck is equipped with a Urea/DEF tank, it shall be clearly labeled as such.

Complies: |_| Yes |_| No Note: A drain plug shall be provided in the bottom and end section of the tank(s).

Auxiliary Step:

An additional step shall be placed at or just below the bottom of fuel tanks or SCR systems that do not provide a safe step height of ±18” from level ground. Step offset shall maintain equal footing from first step to cab sill.

Complies: |_| Yes |_| No Surface area to be not less than that provided with standard tank step and covered with open-grated, anti-skid material. The step shall be Stainless steel, aluminum or powder coated steel.

Visual example of tank with auxiliary step.

In-Tank Fuel heater:

The truck shall be equipped with a thermostatically controlled fuel heater. The fuel will be heated by circulation through a heat exchanger mounted in the tank, similar to an Arctic Fox or a Department of Transportation approved equal. Circulation shall cease when fuel reaches temperature or when outside temperature does not require use.

Complies: |_| Yes |_| No Component:

Front Wheels & Front Tires:

Wheels shall be hub piloted, disc type, 9.00 DC wide. Steel wheels shall be powder coated standard color. Aluminum wheels standard machine finish.

Complies: |_| Yes |_| No Component:

Front Tires:

Tubeless, first run quality radial, all season over-the-road type truck tire.

Size – 315/80R22.5 Load Range L or as needed to meet G.V.W.R.

Rear Wheels & Rear Tires:

Wheels shall be dual, hub piloted, disc type, 9.00 DC wide with protective inserts between wheels. Steel wheels shall be powder coated standard color. Aluminum wheels standard machine finish.

Complies: |_| Yes |_| No Component:

Rear Tires:

Tubeless, first run quality radial, non-directional, multi-season drive tire designed primarily for on highway use.

Size - 12R22.5 Load Range G or as needed to meet G.V.W.R.

Cab:

Shall be manufacturer's standard air ride, all-weather, insulated, with cloth or vinyl headliner, ventilated with all metal portions treated with rust or corrosion prohibitive material. Interior cab floor shall be coated before assembly with polyurethane performance coating (i.e. Rhino Coatings, Line-X, Raptor).

Complies: |_| Yes |_| No Minimum cab dimensions:

Shoulder room 70" minimum. Inside height from highest point of floor to ceiling of cab approximately 56”.

Windshield and side glass shall be tinted, safety type.

Complies: |_| Yes |_| No Convenience Items:

12 Volt Power points (socket/USB) Dome light Dual arm rests Dual sun visors Interior grab handles with high visibility color or marking. (i.e. Safety Yellow) Exterior grab handle with anti-slip feature (driver’s side) Electronic cruise control Power Windows Power Locks Two ignition keys

Seats, Seat Belts, & Reels:

Driver's seat shall be high-back, air suspension type with operator adjustable lumbar support with arm rest on inside of seat. Passenger seat shall be standard stationary or fixed, unless air is called for in optional accessories.

Complies: |_| Yes |_| No Component:

All seat belts shall be manufacturer’s high visibility color. (i.e. Blaze Orange)

Instruments and Warning Systems:

The following instruments and warning systems shall be furnished:

1. Speedometer

2. Odometer

3. Tachometer

4. Fuel gauge

5. Voltmeter

6. DEF/Urea gauge if equipped

7. Hour meter Must be oil pressure activated or an electric model activated by engine RPM.

8. Engine-coolant temperature gauge with high temperature warning light and chime.

9. Air pressure gauge(s) with low-pressure warning light and chime.

10. Engine oil pressure gauge with low-pressure warning light and chime.

11. Transmission temperature gauge

12. Electronic cruise control

13. Engine air filter restriction

14. Ambient Temperature Display in Factory Instrument Cluster

Radio:

Factory installed, standard AM-FM radio with weather band. Bluetooth connection shall also be provided.

Complies: |_| Yes |_| No Heater & Defroster:

Heavy-duty, hot water, fresh air type with all controls for effective heating and/or defrosting under cold weather conditions. Controls shall be furnished to provide for circulation of “in-cab” air.

Complies: |_| Yes |_| No

Air Conditioning:

Manufacturer’s standard air conditioning with standard manual controls. Controls shall be capable of circulating “in-cab” air without outside “makeup” air.

Complies: |_| Yes |_| No Windshield Wipers:

Type - Dual, heavy-duty, electric, two-speed windshield wipers with intermittent speed control.

Blades - Rubber covered components or beam technology for winter use. If a heavy-duty wiper package for snow & ice applications is offered by the manufacturer, it shall be included. All chassis lights shall turn on when wipers are in use. If remote washer fluid fill is available, it shall be included.

Complies: |_| Yes |_| No Rear View Mirrors:

Type - Dual, power, electrically heated, outside, rear vision and break away type.

Glass mounting –frame or housing mounted.

Size-Approximately ±16" high, 7" wide with heated minimum 6” convex mirror mounted below.

Adjustment - Vertical and horizontal from interior switch.

Complies: |_| Yes |_| No Fender mounted mirrors of size recommended by the manufacturer for chassis and completed truck. They shall include a minimum 6” electrically heated convex mirror, switched on/off with rear view mirrors.

Complies: |_| Yes |_| No Rear View / Back Up Camera System with wash system:

· Color Monitor Displays Camera (Integrated with Force America screen)

· Waterproof and heated Backup Camera (IP69K) with Infra-Red Night Vision

· View displayed as seen (not mirror image)

· Aircraft grade cable connectors

· Washer fluid tank with filtered pump, operator-controlled switch Complies: |_| Yes |_| No Component:

Front Fenders & Hood Assembly:

Shall be constructed of fiberglass or high strength composite and include front fender extensions and flares.

Front fenders and hood assembly shall be a forward tilting assembly with painted, chrome or chrome and painted grille.

Note: Access shall be provided for routine maintenance without removal of the hood assembly or the snowplow push frame.

Complies: |_| Yes |_| No

Front Wheel Splash Guards:

Flexible rubber hanging type splash guards shall be hung from lower rear of the front fenders. The splash guards shall be braced to prevent damage during snow and ice conditions.

Complies: |_| Yes |_| No Paint:

Color – Orange, complying with one of the following:

· Freightliner - #L0140EB

· International - # 3017 - PPG # 61208

· Mack - #8693 – Dupont # P1021

Manufacturers’ standard painting application processes shall be practiced. These may include the use of base coat/clear coat application. Other applications will be considered if discussed and agreed to prior to production. The Illinois Department of Transportation will be the only source to approve any other alternative to the products listed above. Any proposed product must be lead free with low VOC levels. Prior to their approval for color match.

Areas Painted - Cab shall be painted orange. Frame and running gear shall be painted or powder coated manufacturer's standard black.

Note: The cab paint shall match the body paint.

Rust/Corrosion/Oxidation Proofing: (Body) Type – High Performance solvent-based coatings to provide protection against moisture, salt and alkalis.

Method of application - Standard commercial procedures meeting GSA specification A-A-59295, ASTM B-117 Salt spray test and SAE J2334 lab test (1,000 hrs. min.).

Note: Exterior coating color shall be black.

Areas of truck cab to be covered:

Complete underside of cab (All Manufacturers) All areas of the truck cab listed below shall be covered unless these areas are made of fiberglass, high strength composite or other rust, corrosion or oxidation proof material.

· Inside door panels

· Inside door posts

· Inside rocker panels

· Inside of cab rear wall

· Inside light wells

· Inside fender wells

· Inside hood Areas of dump body to be coated:

· Underside of dump body

· Rear corner post of body (if interior pockets are not powder coated)

· Longsills of dump body Complies: |_| Yes |_| No Component:

Rust/Corrosion/Oxidation Proofing: (Chassis- After truck completion before delivery) Type – High Performance Eco-friendly Oil-based coatings to provide protection against moisture, salt and alkalis.

Method of application - Standard commercial procedures per manufacturer’s recommendations.

Note: Exterior coating color shall be black (i.e., Fluid Film Black or NHOU Protective Coatings).

Areas of chassis to be covered:

· Frame, brackets and weldments

· Suspension, axles, axle housings and attached components Complies: |_| Yes |_| No Component:

Note: SDS informational sheets shall be included in each truck with delivery.

Important Information Regarding the Mounting and Installation of Body Installers Components:

The Department of Transportation is aware that various truck cab-chassis configurations and engine types will greatly influence the location of required component equipment. For these reasons, the Department does not specify specific locations for the various components; however, it does reserve the right to approve the location of all component equipment.

Complete pilot models with all components installed in the proposed location for each item unit covered by this specification shall be made available for inspection and approval purposes prior to production of the remaining order. After contract award, any questions or further information regarding these components or their installation can be obtained by contacting the Department of Transportation. All questions prior to contract award shall be sent to the procurement contact listed in BidBuy.

II. Special Truck Wiring:

Special Emergency Lighting, Truck Wiring and Switches:

Emergency lighting and wiring is a critical component of the Department Snow Removal and Maintenance Trucks. It is the intent of the Department that for the safety of IDOT personnel and general traveling public that the complete unit be installed as a system, to offer the most reliable and adequately illuminated truck possible. It is imperative that the system be installed meeting or exceeding industry standard, SAE J2498_201611, dated 2016-11-03.

General Requirements:

All wiring terminal connections shall be crimped and soldered. All wiring must be uninterrupted and completed without splices of any kind. Weather pack type connectors used at lighting, accessories, etc.

Complies: |_| Yes |_| No All auxiliary wiring from the truck cab shall pass through a rubber boot type firewall grommet on the floor of the cab or Factory integration module with weather tight connection. All non-factory holes for wiring shall be grommeted and sealed with 100% high temp silicone. The wiring shall be made continuous from cab to all lights and backup alarm as described below. Weather pack connections where needed for sub-harnesses; adequate slack in harness to prevent chaffing during cab movement. Quick-disconnect type lead splices are not acceptable.

Complies: |_| Yes |_| No

All lights and backup alarm shall have a common ground lead returning to the in-cab junction box. This ground shall be a buss style with a #4 strap run to truck batteries. All body company wiring shall be grounded from this source.

Complies: |_| Yes |_| No Note: All ground wires in Special Body Wiring harnesses are to be 14 gauge minimum.

All body and cab shield-mounted lights, wiring, and junction boxes shall combine to form a sealed waterproof system for commercial vehicles, utilizing standard production wiring harnesses where practical.

Complies: |_| Yes |_| No Locations and installations of all wiring are subject to approval from the Department of Transportation.

Complies: |_| Yes |_| No The successful bidder shall furnish a simple wiring diagram of the special wiring installation to each engineer at each of the delivery destinations.

Complies: |_| Yes |_| No All lamp connections and all junction box post connections, along with all internal and external pins in wiring couplers or receptacles shall be treated with a non-conductive corrosion inhibitor.

Complies: |_| Yes |_| No A ground strap of #4 battery cable with eyelets shall be run from a stud welded to the body longitudinal member and bolted to a clean suitable location at the rear of the truck frame.

Complies: |_| Yes |_| No The wiring harness shall be continuous and include color coded wire. Each wire in the harness shall be embossed with the function it services through the length of the harness. All conductors within the harness shall be 14 gauge wire minimum. Weatherproof Canbus systems can be utilized.

Complies: |_| Yes |_| No Routing, Fastening, Sealing and Grommeting shall be as required to effectively protect the various leads and harnesses from sagging, chaffing, corrosion and vibration.

Complies: |_| Yes |_| No Special Trailer Harnesses and TMA power supply:

Type - Continuous color coded, 7-conductor from truck cab to end of truck frame for operation of trailer lights and electric trailer brakes. Non-ABS and ABS with combination Stop/Turn/Tail lights. Trailer plug harness shall be sealed at connectors with silicone rubber type electrical sealant to prevent corrosion (ASI 388 or equal).

Connector – Green ABS 7-way ATA approved socket with weather cap.

Black Non-ABS 7-way ATA approved socket with weather cap.

Conductor Use:

1. Ground to towing vehicle.

2. Clearance and identification lights.

3. Left turn signal and disability lights.

4. Stop lights.

5. Right-turn signal and disability lights.

6. Tail lamps, three-bar marker lamps and other clearance or marker lamps.

7. Anti-lock brake device / Battery.

Complies: |_| Yes |_| No Two (2) labeled 10-gauge wires shall run from fused battery source and ground to rear of truck chassis at pintle plate supplying power for TMA arrowboard. Wires shall terminate with weatherpack or Duestch type connecter.

Note: Lighting conductors to be continuous to in-cab junction block. Brake conductors to be continuous to under dash area with ample lead for later installation of electric brake controller by the body company. Brake conductor leads shall be labeled, coiled, and secured in an accessible location under the truck dash area. Specific wiring instruction will be provided by the Department of Transportation prior to final assembly.

The Switch Panel shall be in the dash configuration or equivalent.

Complies: |_| Yes |_| No Switches:

Panel Switches shall be function programmable and include:

Day-Night (Switch for LED Warning Lights) Emergency LED warning lights Camera wash system Plow LED lights Pre-wet tank LED light Spreader LED Light(s) Air Tailgate w/guard Wing LED Light Auxiliary switch (spare) Complies: |_| Yes |_| No The above switch functions shall be back lit in the panel by LED and increase in brightness when activated.

Complies: |_| Yes |_| No All switches shall carry a manufacturer’s warranty.

Complies: |_| Yes |_| No Warning indicators for Hydraulic Oil Low (Blue) and Body Height (Red) shall be displayed in the operator’s station. The warning indicators shall flash when activated and the body height indicator shall include an audible alarm when activated. See body height indicator.

Complies: |_| Yes |_| No The switches shall be self-protecting and must not reset until the short circuit or over-load condition is corrected.

Complies: |_| Yes |_| No A 50-amp thermal breaker with manual reset shall be provided in the wire between the power source and the switch panel. The breaker shall be within 18” of the battery source prior to entering the cab and in a protected location.

Complies: |_| Yes |_| No

Special Power Distribution and Mounting Center:

The Power Distribution Center shall consist of the installation of a constant duty relay, LED warning light power module, air tailgate valve, spreader control module, and power distribution center. All modules shall be individually sealed (potted) units with protected, weather-proof connectors. Location for this Power Distribution Center shall be between seats along the back wall of the cab, under passenger seat and have the capability to protect all components from possible damage.

Requirements:

A minimum 75 ampere constant-duty magnetic type relay shall be provided to remove specified accessory circuits from the ignition key switch to prevent switch overloads, yet retaining key switch on-off control. The relay shall be a Bosch-75 amp relay or a Department of Transportation approved equivalent. Circuit breaker board with minimum of (6) accessible terminals for connection of IDOT radio, spreader and joystick control power module, LED warning light module, and the electric trailer brake control if required with either resettable or ATC fuses sized appropriately. The air tailgate valve for control of dump body tailgate latch mechanism will also be located here.

Accessible terminals shall also be available for controlling additional IDOT installed electrical equipment.

Installation and the use of alternative products will be subject to prior approval of the Illinois Department of Transportation.

Component:

A fuse panel and ground bar capable of supporting a constant 20-amp current draw shall be provided within the cab electrical junction center for installation of IDOT Radio/AVL equipment. This fuse panel will be separate from the main distribution fuse panel for snow and ice system.

Complies: |_| Yes |_| No A 35-amp circuit breaker with 10-gauge two wire circuit from cab electrical center to rear pintle plate shall terminate with weather pack type connector for future TMA connection.

Component:

A 150-amp Thermal breaker with manual reset shall be provided for the Standard Dump Body Vibrator. Any additional relays or wiring needed for proper connections shall be included.

LED Auxiliary Snow Removal Headlights with Park/Turn Lamps and LED Plow Markers:

The auxiliary headlights shall be heated, full LED including outboard mounted park/turn, Vignal 3832-0090, J.W. Speaker 0555743 or IDOT approved model. The design utilizing tempered glass lens or hard coated polycarbonate so it will not fade or fog. The design of the light shall enhance the transfer of the heat generated by the LED(s) and heat grid to the lens to keep them free of snow and ice build-up.

Component:

Complies: |_| Yes |_| No Shock mount adjustable sockets attached to heavy 304 stainless steel support brackets or factory fender mirror mounts. Support brackets shall be securely mounted providing a minimum height-to-center of sealed beam of 70” above road surface. Mounting through the fiberglass will require an isolation type mounting. Final location and installation subject to Department of Transportation approval.

Complies: |_| Yes |_| No Headlights (LEDs) shall be clear - Park/turn lights (LED’s) – amber when lit.

Complies: |_| Yes |_| No

Headlight/Plow and Plow Marker light switching control shall be located in the dash and provided by the truck manufacturer or body company. Wiring for the plow lights shall be furnished and routed by the truck manufacturer to a location near the front grill area. There shall be weather tight connections for attachment of the plow light/turn signals and plow markers.

Note: If the Plow light controls are integrated in the factory body control module the vendor or manufacturer shall make available to the Department of Transportation the proper diagnostic tools, personnel, or parts to test and repair the system during a snow emergency.

Complies: |_| Yes |_| No Auxiliary park/turn lamps to operate in unison with standard park/turn lamps.

Complies: |_| Yes |_| No Operation in Auxiliary Mode requires a combination light control switch and dimmer switch control for auxiliary headlights so standard headlights are not on.

Complies: |_| Yes |_| No The high beam indicator in the dashboard shall function in either mode of headlight operation.

LED Light Bar:

Type- The light bar shall be 72" in length with a maximum height of 3.75 inches, a depth of 12”, and designed for aerodynamic efficiency. The main structure shall be of heavy gauge extruded aluminum.

Complies: |_| Yes |_| No The light bar’s outer lens shall be clear and constructed of polycarbonate. Each section must be completely sealed and attached to the base with screws. Each lens must be easily removable without removal of the light bar from the roof.

Complies: |_| Yes |_| No The light bar shall contain one (1) control module I/O board which shall contain all the electronics required to operate a minimum of six (6) internal Super-LED amber light modules. The LED light modules will be located at each of the four corners of the bar with the additional located inboard forward facing, or to the Department’s requirements. Each light module shall be independent and shall be easily removable without removal of the light bar from the roof of the cab.

Complies: |_| Yes |_| No Note: IDOT is aware light bar design may have to be altered to include solar panel(s) mentioned previously in specification.

Location - Mounted to the cab roof. Mounting brackets shall include a minimum 7" cast aluminum riser with an aluminum angle mounting bracket for the two-way, radio antenna. Mounting brackets to be securely fastened using stainless steel hardware. Note: Roof to be adequately reinforced by the truck manufacturer and all mounting subject to IDOT approval.

Component:

Note: Mounting the light bar to the truck cab will be reviewed with the successful body company and approved during pilot inspection.

Safety/Warning Light Control System:

The control system shall feature situation-based integration with scene specific functions utilizing various vehicle components and signals. The control system shall be able to control and vary voltage and lighting patterns to reduce night glare depending on operational conditions. The control system at a minimum shall include the following:

· Dynamic Variable Intensity (DVI) flash patterns

· Can Bus Technology

· Remote Connectivity

· Firmware Updates through USB-C

· 8 Minimum inputs / 16 outputs

· Expansion capabilities

· Photocell

· Remote vehicle to vehicle synchronization

· 4 position select switch with push button controls Complies: |_| Yes |_| No Component:

The system shall meet or exceed SAE J845 Class 1A, June 2013. Omnidirectional Light bar shall be certified by an AMECA-accredited testing lab to meeting these requirements in the appropriate specified safety colors. The Amber shall meet or exceed Amber J845 Class 1S (130), the Clear shall meet or exceed Clear J845 Class 1S (120), the Amber Vertical shall meet or exceed Amber J845 Class 1S (40), the Clear Vertical shall meet or exceed Clear J845 Class 1S (40) June 2013. Certification document to be included with bid.

LED-Combination Tail/Stop and Rear Signal:

Type - Dual combination 4 1/8” X 6 1/2” Class A, LED, sealed, shock mounted, capable of flash alert pattern before steady burn.

Location - Rear of truck chassis mounted to pintle plate.

Lens color - Red.

Taillight control - Combination light control switch.

Brake light control - Brake control.

Turn signal control - Turn signal control switch and 4-way hazard warning switch.

Complies: |_| Yes |_| No Additional Body-Mounted Rear Stop/Tail and Turn Signal LED Lights:

Type - Dual, oval 2” x 6” single-face, sealed, shock mounted, High Intensity LED capable of flash alert pattern before steady burn.

Location - In the dump body rear corner braces.

Lens color - Red.

Control - In series with standard stop/tail and turn signal lights.

Complies: |_| Yes |_| No Additional Body-Mounted Rear LED Lights:

Type - Sealed LED designed with 180o light pattern, mounted in a 7 gauge heavy-duty stainless steel narrow aerodynamic angled leading edge housing not to exceed 2 9/16” in width. Stainless steel housing to accommodate three (3) Linear Super LED’s approximately 1 5/8” x 5” in size. All warning lights to be wired into a single central encapsulated flasher unit. Automated tempered glass lens heating system shall keep lenses clear of snow and ice.

Location – Along each side of the rear of the dump body rear corner positioned in front of the rear marker light and mounted as high as possible, while remaining within the limits of the rear corner.

Flashing sequence – Flashing light sequence to flash high and low LED and then center LED with opposing flash sequence on each side.

Color – Amber - Top & bottom (2 each light – heads per housing). White - center.

Wiring – All cabling shall be salt, chemical, and oil resistant TPR style. All connections shall be “Deutsch” or “Weather Pack”.

Control - Special circuits with power supplied through the switches on the console.

Warranty – All LED warning lights and flashers to be warranted for a minimum of 5 years.

Complies: |_| Yes |_| No Component:

Additional Cab Shield-Mounted Rear Stop/Tail and Turn Signal LED Lights:

Type – Dual, 4 1/8”H x 6 1/2"W, LED, single-face, sealed, shock mounted, High Intensity LED S/T/T lights, capable of flash alert pattern before steady burn.

Location - Top of cab shield at each end.

Lens color - Red.

Control - In series with standard stop/tail and turn signal lights.

Special guards - Heavy steel with enclosed back and sides and removable top for access designed to protect light assembly from heavy shocks, yet provide a clear view of lights from the rear at all dump body angles. The wiring for each light shall be in conduit or tube along the inside front of the cab shield.

Complies: |_| Yes |_| No

Additional Cab Shield-Mounted LED Warning Lights:

Type – Dual 4 5/16”H x 6 3/4”W x 1 3/8”D warning lights. The warning lights shall incorporate Linear Super-LED and Smart technology. Each light head shall be populated with a minimum of (18) amber and (18) white Super LED’s and be covered with a clear optic hardened automotive lens. The lens shall seal against moisture, dust and other environmental conditions. The light pc board shall be conformal coated and mounted in the light base. The light head shall include approximately 160 different flash patterns. The Flash pattern shall be reviewed with IDOT representatives prior to production.

Location - Top of cab shield at each end next to the S/T/T lights on the special guards.

Special guards - Heavy steel with enclosed back and sides and removable top for access designed to protect light assembly from heavy shocks, yet provide a clear view of lights from the rear at all dump body angles. The wiring for each light shall be in conduit or tube along the inside front of the cab shield.

Complies: |_| Yes |_| No LED-Rear Identification Lights (3-Bar):

Type - Three, single-face, LED, sealed, and shock mounted with grommet approximately 2 1/2” in diameter.

Location - Rear of dump body.

Lens color - Red.

Control - Combination light control switch.

Complies: |_| Yes |_| No LED-Body Clearance Lights:

Type - Single-face, LED, sealed, and shock mounted with grommet approximately 2 1/2” in diameter.

Location - As required.

Complies: |_| Yes |_| No

Reflectors As required by Illinois State law.

Complies: |_| Yes |_| No All LED warning lights along with the LED S/T/T lights shall be hard coated polycarbonate and be warranted for a period of 5 years.

Complies: |_| Yes |_| No LED Spreader Lights:

Location – Dual LED type lights mounted under the right and left rear dump body corner posts. The lights provide a diffused light at spinner assembly of a conventional under-the-tailgate or slide-in hopper body material spreader.

Housing – Rubber with stainless bracket and hardware.

Lens color – White/Clear Control - Switch and circuit shall originate in the dash console.

Complies: |_| Yes |_| No Body Height Indicator:

Type – Electric/Visual/Audible.

Indicator Light(s) and Audible Warning - Dash mounted or spreader control display with appropriate labeling.

Actuation Height - Bed up alert in display Alarm Actuation Height - 12'6” measured to front lip of cab shield activates constant alarm, no override.

Sensing Device Location - Body subframe or rear corner post.

Sensing Device Enclosure - Watertight, shock and corrosion resistant.

Wiring - Continuous with polyvinyl or equal insulation.

Standard Dump Body Height Reference Light:

Type – ¾’ Round Waterproof LED mini clearance light with grommet.

Location- Lower left front corner of drivers side front dump body corner post.

Lens color- Amber Control – Combination light control switch/Running lights

Radio / Tablet Pre-wire:

Vendor shall install agency-provided hardware in configuration similar to those on present agency trucks.

Complies: |_| Yes |_| No Backup Alarm:

Type - Electric, Preco 1040, Ecco, Whelen or equivalent.

Sound level – Self adjusting 87 to 112 decibels +5, measured at 4’.

Location - Inside of frame near the rear of the chassis.

Wiring - Continuous to the backup light terminal of the special junction box described herein.

Component:

III. Truck Frame Mounted, 240 Gallon Pre-wet System:

This system shall be complete and functional for dispensing measured amounts of snow and ice control chemicals in conjunction with the specified spreader control.

Complies: |_| Yes |_| No Construction and construction practices shall feature corrosion resistant materials and methods.

Complies: |_| Yes |_| No The system shall be complete including pump, flow meter, nozzles, hoses, tank(s), fittings, wiring, and mounting hardware. All shall be tested for operation and leaks prior to delivery.

Complies: |_| Yes |_| No Pump:

A hydraulic driven positive displacement bronze gear pump shall be plumbed to receive oil from the main valve stack. The pump shall be rated at a minimum 7gpm and be direct coupled to the hydraulic motor. It shall have a stainless steel shaft with bronze bearings, grease zerk and adjustable internal bypass factory set at 45psi.

Complies: |_| Yes |_| No The flow meter will be of paddle style design. The pump, flow meter and related components shall be mounted within a NEMA fiberglass enclosure near the outside rear of the truck cab. The electrical connection shall be an M12 connector and be compatible with the specified spreader controls.

Complies: |_| Yes |_| No The pump, plumbing and specified control system shall be able to supply 20-45 gallons of liquid per ton of salt.

Complies: |_| Yes |_| No Mounting:

The mounting shall not hinder or interfere with routine truck or body maintenance.

Complies: |_| Yes |_| No The stainless steel mounting shall provide full containment and provide support for the bottom and all sides of the reservoirs.

Complies: |_| Yes |_| No The mounting shall be constructed of welded 304 or 201 austenitic stainless steel .188” thick, approximately 17 1/2” x 78” x 60” with a shear strap mounting for the reservoir(s).

Complies: |_| Yes |_| No

Two (2) lifting eyes shall be provided for balanced pickup of the mounting assembly and reservoir(s).

Complies: |_| Yes |_| No The reservoir(s) mounting shall be completed with 304 or 201 austenitic stainless steel brackets and hardware.

Complies: |_| Yes |_| No The reservoir(s) shall be mounted and secured in a manner that prevents damage due to rubbing, chaffing, etc.

Complies: |_| Yes |_| No Reservoir(s):

The reservoir(s) shall be constructed to fit in an open area behind the truck cab approximately 60”W x 15 1/2”D x 60”H, and not interfere with dump body operation or routine maintenance procedures.

Complies: |_| Yes |_| No The reservoir(s) shall have a minimum 240-gallon capacity, with internal baffles, and allow for dual product conversion. Dual reservoirs shall be plumbed to equalize.

The reservoir(s) shall rotation molded and UV stabilized polypropylene material, natural color, with a minimum wall thickness of .350”, rated for liquids weighing 14.5 pounds per gallon.

Each reservoir shall include a minimum 10” diameter threaded poly…