Type 6 Fire Engine_Model 643U_Apparatus Body Only_March 2026.pdf

Type 6 Fire Engine — Model 643U Apparatus Body Only Specification

Issue Date: March 2026

Supersedes: May 2025

Type 6 Fire Engine, Model 643U – Supersedes May 2025

TABLE OF CONTENTS

RECORD OF REVISIONS

1 — GENERAL

1.1 General Statement

1.2 In-Service Weight

1.3 NFPA 1900 Requirements

1.4 Tilt Test

1.5 Apparatus Body Material

1.6 Auxiliary Pump

1.7 Brand Name or Equivalent Products

2 — CHASSIS ELECTRICAL REQUIREMENTS

2.1 Chassis Electrical Additional Equipment and Modifications

2.2 Multiplex System

2.3 Master Body Disconnect Switch

2.4 Battery “On” Indicator Light

2.5 Junction Connection and Location

2.6 Bulkhead Connections

2.7 Ground Lighting

2.8 Back Up Alarm

2.9 Antenna

2.10 Radio Pre-Wire

2.11 Rear View Backup Camera

2.12 Tire Pressure Monitoring System (TPMS)

3 — TRAFFIC WARNING SYSTEMS

3.1 Traffic Warning System

3.2 Electronic Siren

3.3 Speaker

3.4 Forward Upper Zone A/B/D Light Bar

3.5 Forward Lower Zone A Warning Lights

3.6 Forward Zone B/D Warning Lights

3.7 Aft Zone C Warning Lights

3.8 Headlight Flasher

4 — CHASSIS ADDITIONS AND MODIFICATIONS

4.1 Modifications Required

4.2 Apparatus Fluid Types and Quantities

4.3 Seating Capacity

4.4 Seating

4.5 Seat Belt Warning

4.6 Vehicle Height/Weight/Length Warning

4.7 Final Stage Manufacturer Vehicle Certification

4.8 Noise Hazard Warning

4.9 Air Filter Ember Protection Screen Warning

4.10 “Do Not Move Apparatus” Warning

4.11 Cab Console

4.12 Switch Panel

4.13 Front Bumper Brush Guard

4.14 Winch

4.15 Auxiliary Offroad Driving Lights

4.16 Rear Bumper

4.17 Mud Flaps

4.18 Exhaust System

4.19 Fuel Hose and Electrical Harness Protection

4.20 Chassis Air Intake Ember Guard

4.21 Cabin Air Ember Guard

4.22 Front Tow Hooks

4.23 Rear Tow Hooks

5 — APPARATUS BODY DESCRIPTION

5.1 General Body Construction

5.2 Body Materials

5.3 Installation of Hardware

5.4 Threaded Parts

5.5 Apparatus Body

5.6 Body Mounting

5.7 Vertical Surfaces

5.8 Grab Handles

5.9 Rear Steps

5.10 Compartmentation

5.11 Compartment Configuration

5.12 Driver's Side Compartments

5.13 Passenger's Side Compartments

5.14 Storage of Flammable Materials Warning

5.15 Compartment Doors

5.16 Door Latches and Hardware

5.17 Door Hold Open Devices

5.18 Adjustable Shelf Channels

5.19 Compartment Shelves

5.20 Compartment Venting

5.21 Compartment Floor Mats

5.22 Compartment Door Threshold Protection

5.23 Pump Area Doors

5.24 Rear Cab Protection

6 — PUMP AND PLUMBING

6.1 Accessories Provided

6.2 Auxiliary Pump

6.3 Pump Specifications

6.4 Pump Option - Auxiliary Pump (Gasoline Engine-Powered Pump)

6.5 Pump Specifications (Gasoline-Powered Pump)

6.6 Fuel Cell

6.7 Rear Mounted Pump Operator's Panel

6.8 Plumbing Components

6.9 Pump Panel and Plumbing Lights

7 — VALVES, CONTROLS, GAUGES AND PLUMBING REQUIREMENTS

7.1 Discharge and Intake Plumbing

7.2 Truck Identification and Pump Performance Plate

7.3 Pump Operating Instruction Plate

7.4 Test Gauge Connections

7.5 Winterization Port

7.6 Pump Panel Labeling

7.7 Discharge Pressure Gauge

7.8 Intake Pressure Gauge

7.9 Pump Cooler/By-Pass

7.10 Water Tank Level Electronic Gauge

7.11 Priming Pump

7.12 Stainless Intake Strainer

7.13 Discharge Locations

7.14 Intake Location

7.15 Tank Fill

7.16 Tank to Pump Line

7.17 Booster Hose Reels

7.18 Foam Proportioning System

7.19 Pump Performance Test and Certification

8 — WATER TANK

8.1 Construction

8.2 Clean Out Plug

8.3 Tank Capacity

8.4 Foam Tank

8.5 Gear Storage Compartment

8.6 Ice Chest Storage

8.7 Spare Tire Storage

8.8 Miscellaneous Storage

9 — BODY ELECTRICAL REQUIREMENTS

9.1 General Electrical Statement

9.2 Recessed Lighting

9.3 Rear DOT Lighting

9.4 Taillights, Brake Lights

9.5 Turn Signal Lights

9.6 Back Up Lights

9.7 License Plate Bracket and Light

9.8 Cluster/Clearance Lights and Reflectors

9.9 Rear Traffic Advisor

9.10 Compartment Lights

10 — ELECTRICAL SYSTEM PERFORMANCE TEST, LOW-VOLTAGE

10.1 Test Requirements

10.2 Test Sequence

10.3 Reserve Capacity Test

10.4 Alternator Performance Test at Idle

10.5 Alternator Performance Test at Full Load

10.6 Low Voltage Alarm Test

10.7 Documentation

11 — APPARATUS FINISH

11.1 Apparatus Color

11.2 Apparatus Body Finish

11.3 Vehicle Marking

11.4 Door Decal (Shield and Vehicle Numbers)

11.5 Compartment Identification

12 — EQUIPMENT

12.1 Equipment Provided

12.2 Manuals and Drawings

12.3 Road Kit

12.4 Wheel Chocks

12.5 Hydrant Wrench Holder and Wrenches

13 — WARRANTY PROVISIONS

13.1 10 Year Apparatus Warranty

13.2 Water Tank Warranty

Record of Revisions

Date Revision summary

April 2009 • Initial Release August 2009 • Revision March 2010 • Revision

February 2011 • Revision August 2011 • Revision

May 2013 • Added Table of Contents

• Added Record of Revisions

• Clarified radio pre-wire requirements

• Deleted green aviation light from light bar

• Clarified that front bumper bolt-on brush guards are not acceptable

• Deleted mobile attack bracket requirement

• Refined chassis component (skid plate) requirements

• Clarified grab handle requirements

• Added requirement for flammable material storage warning label

• Increased number of shelves from eight to nine

• Added shelf to passenger side forward compartment

• Deleted vent from passenger's side lower aft compartment

• Added vent to door face and rear wall of driver's side aft compartment

• Revised auxiliary fire pump specifications

• Revised optional pump specifications

• Revised pump panel requirements

• Added heading for “Valves, Controls, Gauges & Plumbing

Requirements”

• Changed discharge pressure gauge from 600 P.S.I. to 400 P.S.I.

• Clarified that foam system cannot be mounted in a storage compartment

• Revised standard vehicle markings

• Revised wheel chock requirements and deleted requirement for lanyard

• Deleted requirement for swivel hooks

• Revised warranty to ten years

• Added standard vehicle marking drawing

Date Revision summary

August 2015 • Updated Format

• Added specification for inline check valve on foam system

• Added Brand Name or Equivalent direction

• Updated Lightbar Size and Brand

• Changed lower zone C lights from amber to red

• Deleted amp meter

• Added hour meter

• Updated Pump Water Level Gauge

February 2016 • Updated Format

• Minor Editing

• Modified Junction Box wording to require no interference with seating location leg room

• Modified location of master body disconnect switch

• Added third rear step

• Changed road kit fire extinguisher to 5 pounds

• Added diamond plate requirement to the outside/rear of the driver's side upper module

• Added additional hose reel push button switch

• Added hose reel nozzle brackets

• Added requirement for bulkhead perimeter lighting to be installed below the hose reel nozzle brackets

• Modified placement of the left and right-side hose compartment

• Revised lightbar standard and clarified Traffic Advisor

• Updated auxiliary pump

May 2017 • Revised skid plate

• Revised front bumper requirement

• Added in-service weight requirement

• Updated tank to pump and intake line size

• Added protective housing for foam system

• Added electrical requirements for foam system

• Added rear view camera

• Added USB charging ports

• Amended chock block mounting location

• Updated vehicle marking diagram and locations

Date Revision summary

• Added front license plate bracket

• Amended dunnage compartment

• Amended and added hose reel requirement

• Amended chassis component protection

• Amended Chassis Air Intake Ember Guard

• Amended cup holders

• Added in cab water level display

• Deleted passenger & driver side pre-connect compartments

• Amended door latches and hardware

• Amended junction box

• Amended back up alarm

• Amended antenna mounting bases

• Amended entire chapter for Traffic Warning Systems

• Deleted apparatus fluid types and label

• Amended exhaust system

• Amended compartment venting

• Amended rear cab protection

• Amended hose rollers

• Amended discharge pressure gauge

• Amended compartment lighting

• Amended rear traffic advisor

• Amended gear storage compartment

• Amended ice chest storage

• Amended spare tire storage

• Changed/amended chainsaw storage to misc. storage

• Changed paint from FED-STD to No. 14260 of SAE AMS- STD-595

Rev. A (Forest Service Green)

• Amended foam system requirements

February 2018 • Revised pump cooler/pump bypass requirements

• Added tire pressure monitoring system

• Added rearview backup camera system

• Revised brand names or equivalents statement

• Revised traffic warning system main item

October 2020 • Revised emergency lighting requirements

Date Revision summary

• Revised rear taillight and turn signal requirements

• Added front and rear tow hooks

January 2022 • Revised vehicle markings

• Added operator over-ride switch to back-up alarm

• Revised wheel chock

• Revised apparatus body material

• Revised apparatus body finish

• Revised body frame construction

• Revised body mounting

• Revised vertical surfaces

• Revised rear cab protection

• Revised junction box

• Changed “perimeter lighting” to “ground lighting”

• Revised auxiliary off road driving light

• Deleted tubular exhaust system protection

• Deleted chassis component protection

• Revised compartmentation

• Revised auxiliary pump

• Deleted standard vehicle marking diagram

• Added door decal

October 2022 • Revised tire pressure monitor system (TPMS) March 2023 • Revised back up alarm

• Changed NFPA 1906 to NFPA 1900 April 2024 • Added winch

• Revised front bumper to accept winch capability

• Revised auxiliary offroad driving lights

March 2026 • Revised Junction Box

• Revised Auxiliary switch labeling

• Revised cab console

• Revised switch panel

• Revised compartment dimensions

• Revised low pressure feature

• Revised Pump capacities

Date Revision summary

• Added requirements for apparatus drawings [Future revisions] • This space is reserved for future revisions.

1 — General

1.1 General Statement

1.1.1 The utility body described in this specification shall be mounted on Government furnished cab and chassis. The apparatus manufacturer shall be liable for all loss and damage to Government furnished cab and chassis until completion and final acceptance of work and returned to the Government.

1.2 In-Service Weight

1.2.1 The in-service weight shall not exceed the OEM chassis front axle rating and 90% of the rear gross axle weight rating and suspension ratings when: fully loaded with water, foam and fuel, with 250 pounds per seat, and 1300 pounds of equipment evenly distributed in the storage compartments.

1.3 NFPA 1900 Requirements

1.3.1 The completed apparatus described in this specification shall be compliant with the requirements of National Fire Protection Association (NFPA)1900, latest edition, except where noted.

1.4 Tilt Test

1.4.1 The apparatus shall be tilted to 30° minimum before lifting a tire or tire set when tested at the estimated in-service weight in accordance with NFPA 1900.

1.5 Apparatus Body Material

1.5.1 The apparatus body shall be designed and constructed of materials consistent with current fire apparatus engineering technology and design standards.

1.6 Auxiliary Pump

1.6.1 The auxiliary pump for this apparatus shall be specified by the Government.

1.7 Brand Name or Equivalent Products

1.7.1 Products equivalent to the brand name components specified herein may be approved by the Government. Equivalent products shall not be used unless approved in writing by the Government prior to contract award and documented in the resultant contract. After the contract award, approvals for equivalent products may be considered, and if approved, shall be documented in writing by the Government.

2 — Chassis Electrical Requirements

2.1 Chassis Electrical Additional Equipment and Modifications

2.1.1 The apparatus chassis shall be equipped with a heavy-duty 12-volt direct current (VDC) negative ground electrical system. The electrical system shall include all parts, components, switches, relays, wiring, and other devices required to assure complete, consistent and proper operation of the completed apparatus. Wiring shall be routed and/or protected to eliminate exposure to moving parts or debris.

2.1.2 The electrical system will be fabricated in modules as is the apparatus. The body and chassis will be individually wired as independent modules and connected as a completed unit at the final assembly via bulkhead type waterproof electrical connectors located in the body floor adjacent to the electrical compartment. All GXL/SXL wiring for the apparatus body will be within a temperature resistant harness rated at a minimum of 280 degrees Fahrenheit. All wires in each harness must be color and function coded. Wiring will be run along structural rails and tied in a neat and orderly manner. Wiring shall be routed and/or protected to eliminate exposure to moving parts or debris. Wiring passing through compartments shall be protected from tears, abrasions, and cuts caused by loose item moving in the compartment space.

2.1.3 All lights are required to comply with Federal Government Codes for vehicles of this size and design shall be provided and installed. These lights shall include headlamps and front turn signals with hazard switch, cab marker and clearance lights, back up lights, stop-turn-tail and license plate lights.

2.1.4 All switches for the warning lights and other electrical equipment shall be mounted on a separate switch panel located in the cab on a master electrical console mounted between the two front seats. The switches shall be functionally laid out, properly identified, and shall be located within easy reach of both the driver and the officer. The warning light system shall have a “master” switch, which shall allow for the pre-selection of all warning lights. All switches shall be of a heavy-duty design.

2.1.5 The following additional electrical equipment shall be installed on, and modifications performed to, the specified cab and chassis by the apparatus builder:

2.2 Multiplex System

2.2.1 A multiplexed solid-state management system for controlling the electrical system devices shall be provided. The system shall be fully programmable, and capable of performing load management functions, system monitoring and reporting. All electrical circuits and wiring shall be rated at 125% of the maximum load being imposed.

2.3 Master Body Disconnect Switch

2.3.1 One master body disconnect switch shall be provided in the cab. The switch shall be rated for 175 amps continuous duty and 800 amps intermittent duty. The switch shall be labeled “ON/OFF” and shall be located driver's side of the center console's vertical surface near the floorboard. It shall be positioned not to impact the driver's seat or operation of the vehicle.

The exposed terminals shall be protected from damage and inadvertent contact. When in the “OFF” position, all electrical power to the apparatus fire package shall be off. Power to the chassis shall remain separate from this switch. A Cole Hersee™, Model #M-2484-16, with Model #82065 switch plate “ON/OFF” label meets this requirement.

2.4 Battery “On” Indicator Light

2.4.1 One “Battery On” indicator light, with a green lens, shall be provided on the cab center console, located forward on the left side. This light shall illuminate when the battery switch is turned to the “ON” position and the brightness shall dim automatically via multiplexing system when the chassis headlights are turned on.

2.5 Junction Connection and Location

2.5.1 An electrical junction for all apparatus modules, connections, relays, circuit breakers, etc.

shall be located in the cab console. All connection points shall be labeled according to function. Wire length within the console shall be sufficient to allow a minimum of two inches of slack to allow for secure connections and ease of service. All wiring shall be installed in an organized fashion.

2.6 Bulkhead Connections

2.6.1 All apparatus body wiring either entering or exiting the cab shall be in a harness configuration and pass through a centralized location as close to the interior electrical junction as possible. The harness(s) shall terminate at a hermetic bulkhead connector(s), designed to facilitate in the separation of the cab/chassis/apparatus body.

2.7 Ground Lighting

2.7.1 Ten 4-inch clear LED lights shall be provided around the vehicle's perimeter. The lights shall be activated when either the “Ground Lights” switch is activated on the center console, when a cab door is open, or when the vehicle is placed in “blocking mode.” The vehicle is in blocking mode when the vehicle transmission is in “park” with the parking brake set and the emergency master switch turned on with the forward-facing takedown lights off. The Ground lighting “OFF” delay shall be synchronized with the chassis exterior courtesy lighting delay.

2.7.2 Ground light locations shall be as follows:

2.7.2.1 Two lights shall be provided under the apparatus front bumper.

2.7.2.2 Two lights shall be provided facing forward on bulkhead of body, one on each side, installed below the hose reel nozzle mounting brackets.

2.7.2.3 Four lights shall be provided under the apparatus body, one forward and one aft of the rear wheel wells, both sides of the body. The lights shall be housed within an enclosure sufficient to protect from damage within the compartments.

2.7.2.4 Two lights shall be provided under the tail board, protected from impact and debris.

2.7.2.5 The lights shall be wired to the “Ground Lights” switch located in the cab center console.

2.8 Back Up Alarm

2.8.1 One solid state back up alarm shall be provided at the rear of the apparatus protected from impact and debris. The projector shall be mounted in such a manner that debris and dirt does not collect. The backup alarm shall be wired to the reverse circuit of the transmission and shall provide an audible alarm to the rear of the apparatus when reverse gear is selected. The alarm shall have a volume of 87 to 112 decibels while in operation. The alarm shall have a disconnect plug for easy replacement.

2.9 Antenna

2.9.1 Two antenna bases shall be supplied and mounted on the cab roof as specified. The antenna cable shall be routed to the cab interior, terminating at location of radio mounting bracket.

2.10 Radio Pre-Wire

2.10.1 The chassis cab interior shall be wired with battery power, battery ground, switched power, and radio rebroadcast wires to the siren or PA, and labeled to simplify USFS radio installation. The wiring shall allow the radio to be wired “hot”, so the radio is powered with the master body disconnect switch turned off. The radio shall occupy the second forward, angled, position in the cab center console. Exposed positive terminals shall be covered by a protective boot or otherwise protected from inadvertent contact.

2.11 Rear View Backup Camera

2.11.1 If not provided with the chassis, a rear-view backup camera and display shall be provided.

The monitor shall have a minimum display measurement of 6 inches diagonally and be either: 1.) factory installed in-dash with a combination AM/FM/WX radio, or 2.) aftermarket installation separate from the AM/FM/WX radio; professionally installed; mounted in a location approved in writing by the Government. The monitor display shall be shock and vibration resistant; have a high-quality backlit display; and mounting shall not allow vibration. The backup camera shall be high durability and able to withstand harsh vibration;

IP69K rated; and able to withstand 7Gs of force. The camera shall be shipped loose for installation by the apparatus builder. Mounting on top of the dash or in any location that reduces the driver’s field of vision shall not be allowed.

2.12 Tire Pressure Monitoring System (TPMS)

2.12.1 If not provided by the chassis manufacturer, a tire pressure monitoring system shall be installed. Aftermarket tire pressure monitoring systems shall be approved by the government prior to installation. Considerations for the approval of aftermarket solutions will be quality, durability, warranty, repair service, and savings to the Government.

3 — Traffic Warning Systems

3.1 Traffic Warning System

3.1.1 The following traffic warning systems shall be provided and installed on the completed apparatus by the apparatus builder:

3.2 Electronic Siren

3.2.1 The manufacturer shall supply and install one electronic siren (Tomar brand, model 948L- SIREN-R, or equivalent) and digital control panel with 6 auxiliary buttons, 4 position slide switch, 6 position rotary speaker tone selector, traffic director control button, manual siren button, and airhorn button in the cab center console. The control panel shall be flush mounted. The location of the controller shall be convenient to both the driver and the officer.

The siren shall have four basic siren tones: manual, wail, yelp, and hi-lo. The “emergency master” switch shall power the controller.

3.2.2 The manufacturer shall program and label the electronic siren and digital control panel’s auxiliary buttons as follows:

• Auxiliary Switch “1” – Left Scene

• Auxiliary Switch “2” – Right Scene

• Auxiliary Switch “3” – Front Scene

• Auxiliary Switch “4” – Rear Scene

• Auxiliary Switch “5” – Blank

• Auxiliary Switch “6” – Blank

3.3 Speaker

3.3.1 The manufacturer shall supply and install one 100-W siren speaker (Tomar brand, model SPK-100 speaker, or equivalent) mounted behind the driver’s side of the front bumper. The manufacturer shall wire the speaker to the specified electronic siren controller. The manufacturer shall wire the lights to the Tomar brand, model 948L-SIREN-R siren controller, or equivalent located on the cab center console.

3.4 Forward Upper Zone A/B/D Light Bar

3.4.1 The manufacturer shall supply and install one light-emitting diode (LED) lightbar (Tomar brand, model 970-581-0601-6, or equivalent) on the cab roof, facing forward. The lightbar shall be 58 inches wide. Lightbar shall consist of ten dual-color flashing LED modules and two single color, steady burning, red LED modules and two front and two rear flood lights.

Lightbar shall be programmed to specifications provided by the Government.

3.4.2 The light bar shall be mounted to the cab protection headboard and wired to the siren controller slide switch (Tomar brand, model 948L- SIREN-R, or equivalent) in the cab center console (Figure 1). The two forward facing “takedown” modules shall be interlocked with the application of the emergency brake, placing the apparatus in blocking mode and disabling the modules as such. The manufacturer shall mount the lightbar to the rear cab headboard, facing forward and wire it to the “Lightbar” switch in the cab center console.

Figure 1 — LED Lighting Locations and Flashing/Steady Configuration

3.5 Forward Lower Zone A Warning Lights

3.5.1 The manufacturer shall supply and install two dual color LED warning lights (Tomar brand, models R37D-RW-01 (left) and R37D-W- RW-02 (right), or equivalent) with mounting flanges on the front of the apparatus, forward-facing, one per side on the brush guard. The lights shall be waterproof using a vibration-welding sealing process. The lights shall have TIR collimator optics to prevent stray warning light. The lights shall flash red and white at 75 flashes per minute (FPM) in a flicker flash pattern. The lights shall flash in opposite phase of each other when blocking the roadway. The manufacturer shall wire the lights to the siren controller (Tomar brand, model 948L-SIREN-R, or equivalent) located on the cab center console.

3.6 Forward Zone B/D Warning Lights

3.6.1 The manufacturer shall supply and install two dual color LED warning lights (Tomar brand, model RSDV13-RW-01, or equivalent) with mounting flanges on the front corners of the apparatus chassis, side facing, one per side, as low and as far forward as possible on the sides of the hood. The warning lights shall consist of twenty-four LEDs, twelve red LEDs, twelve white LEDs, and with clear Lexan lenses. The warning light shall flash red at 75

FPM. The warning light shall have the ability to override to steady burn white for use as an additional scene light. The lights shall be waterproof using a vibration-welding sealing process. The lights shall have TIR collimator optics to prevent stray warning light. The manufacturer shall wire the lights to the Tomar brand, model 948L-SIREN-R siren, or equivalent controller located on the cab center console.

3.7 Aft Zone C Warning Lights

3.7.1 The manufacturer shall supply and install two 3-inch by 7-inch dual color LED warning/back-up lights on the rear of the apparatus, rear-facing, one per side on the lower rear of the apparatus above the rear step in the bottom position of the common housing with the DOT lights. The lights shall be waterproof using a vibration-welding sealing process. The lights shall have TIR collimator optics to prevent stray warning light. The lights shall flash red and white at 75 flashes per minute (FPM) in a simultaneous flash pattern.

The warning light shall have the ability to override to steady burn white for use as a back-up light. The manufacturer shall wire the lights to the Tomar brand, model 948L-SIREN-R, or equivalent siren controller located on the cab center console.

3.8 Headlight Flasher

3.8.1 The manufacturer shall supply and install one solid-state headlight flasher (Tomar brand, model HF-1 flasher, or equivalent) wired for daytime operation. The flasher shall be a multipurpose type with a high beam activated cut out option. The manufacturer shall wire the flasher to the siren controller (Tomar brand, model 948L-SIREN-R, or equivalent) “Wig Wag” switch located on the cab center console, through the parking brake valve so that it is disabled when the parking brake is applied.

4 — Chassis Additions and Modifications

4.1 Modifications Required

4.1.1 The following additional equipment shall be installed on, and modifications performed to, the specified cab and chassis by the apparatus manufacturer.

4.2 Apparatus Fluid Types and Quantities

4.2.1 A document showing the recommended fluid types and quantities for the apparatus chassis and associated components, shall be provided.

4.2.2 This document shall list the recommended fluid types and quantities for the following components:

• Chassis Engine Lubricant

• Chassis Engine Coolant

• Chassis Power Steering Fluid

• Chassis Transmission Fluid

• Chassis Transfer Case Lubricant

• Chassis Drive Axle Lubricant

• Pump Gearbox Lubricant

• Chassis Brake Fluid

• Transfer Case Fluid

• Front Chassis Drive Axle Lubricant

4.3 Seating Capacity

4.3.1 A warning label listing the seating capacity of the completed apparatus shall be provided in the apparatus cab interior. This label shall be located so that it is visible from all seating positions.

4.3.2 This apparatus shall have a seating capacity of two personnel in front and three personnel in the rear for a total seating capacity of five.

4.4 Seating

4.4.1 The center portion of the 40/20/40 split bench seat shall be removed to accommodate the installation of the console.

4.5 Seat Belt Warning

4.5.1 A warning label, stating: “DANGER- Personnel Must Be Seated and Seat Belts Must Be Fastened While Vehicle is in Motion Or DEATH OR SERIOUS INJURY MAY RESULT,” shall be provided in the apparatus cab interior. This label shall be located so that it is visible from all seating positions.

4.6 Vehicle Height/Weight/Length Warning

4.6.1 A warning label listing the overall height, length, and gross vehicle weight rating (GVWR) of the completed apparatus shall be provided in the apparatus cab interior. This label shall be located so that it is visible from the driver's seating position.

4.7 Final Stage Manufacturer Vehicle Certification

4.7.1 A Final Stage Manufacturer vehicle certification label shall be provided and installed in the apparatus cab driver's door jamb.

4.8 Noise Hazard Warning

4.8.1 A warning label, stating: “WARNING: Noise Hazards Occur During Siren Operation,” shall be provided and installed in the apparatus cab interior. This label shall be located so that it is visible from all seating positions.

4.9 Air Filter Ember Protection Screen Warning

4.9.1 A warning label stating, “This apparatus is equipped with an air filter ember protection screen; routine inspection is required” shall be provided and installed in the apparatus cab interior. This label shall be located so that it is visible from the driver's seating position.

4.10 “Do Not Move Apparatus” Warning

4.10.1 One surface mounted red LED light shall be provided in the center cab console, at the top, or most forward position. The light shall flash whenever side compartment doors are open, and the parking brake is released. The light shall be wired directly into the door ajar switch and hazard circuit. The hazard warning light shall be marked with a label stating, “DO NOT

MOVE APPARATUS WHEN LIGHT IS ON.”

4.11 Cab Console

4.11.1 The cab shall be equipped with an angled front, form-fitted control console located between the front driver's and officer's seats. This console shall be sized to accommodate the installation of a siren controller for the control of the emergency and general illumination lighting, siren controller, traffic advisor, and customer-mounted radios. Panel light brightness shall dim automatically via the multiplexing system when the chassis headlights are turned on. The cab console shall be fabricated from steel and painted with a powder-coated black finish.

4.11.2 The following shall be positioned from forward to aft on the center console as follows:

• One blank faceplate and pre-wiring for Government-mounted radio

• Three microphone clip brackets (shipped loose)

• One switch panel with six switches as described in 4.12.1

• One electronic siren and lighting controller

• two cup holders

• One 2-position 12-volt power outlet

• One 6-inch lockable storage compartment

• Four USB charging ports

• One FRC® Tank Vision Pro 300 Remote Mini Cab Display, or equivalent

• One Map pocket on the side of console large enough to accommodate a three-ring binder but not so large as to interfere with the chassis supplied power points

• Open compartment warning light

• Battery On (Body Master) light

4.12 Switch Panel

4.12.1 The switch panel shall contain a total of four switches with pilot lights, and function labeled, and configured from left to right as follows:

• EMERGENCY MASTER

• GROUND LIGHTS

• WHITE LIGHTS

• AMBER LIGHTS

• CABIN LIGHTS

• HIGH IDLE

4.13 Front Bumper Brush Guard

4.13.1 A heavy-duty black powder coated finish bumper and brush guard assembly shall be provided and installed on the front of the apparatus. The complete assembly shall follow the chassis body lines and encompass the perimeter of the chassis front. The complete assembly shall be of such design that the guard will not vibrate, and shall provide solid mounting area for warning lights, speakers, or other specified equipment. The bumper shall have provisions for a winch. The unit shall conform to OEM chassis manufacturer’s recommendations for not blocking air intake areas or restricting proper airflow through the radiator and engine compartments. Brush guards bolted onto OEM bumper are not acceptable.

4.14 Winch

4.14.1 An electric winch capable of a minimum of 16,500 lb rating and synthetic rope shall be included and mounted to the bumper. The manufacturer shall install the winch according to the recommendations of the winch manufacturer.

4.14.2 The completed apparatus shall be equipped with a recovery kit containing the following items that are rated for a minimum of 1.5 times the GVWR of the apparatus:

• Two synthetic soft shackles

• Synthetic tree protector/saver

• One synthetic recovery strap or rope

• Snatch Recovery Ring

• Winch line dampener

• Gear bag to contain all of the above

4.15 Auxiliary Offroad Driving Lights

4.15.1 LED off-road driving lights shall be installed on the front bumper. The lights shall be switched in the cab console and include a warning label that says “Auxiliary driving light.

For off road use only.”

4.16 Rear Bumper

4.16.1 The rear bumper shall be a minimum of 3 inches tall by 8 inches deep and extend across the width of the apparatus body. The bumper shall be fabricated from heavy duty steel tubing and shall be painted black. The top of the bumper shall be a 4F stainless steel computer numerical control (CNC) punched and perforated skid resistant surface or NFPA compliant skid resistant tread plate surface. The bumper shall protect the apparatus body.

4.17 Mud Flaps

4.17.1 One pair of flexible rubber mud flaps shall be provided on both sides of the apparatus body behind the rear wheels. The mud flaps shall not bear company logo.

4.17.2 The mud flaps shall extend down far enough to be effective but shall not allow the flaps to become entangled with the rear tires when the apparatus is backing up.

4.18 Exhaust System

4.18.1 The exhaust system shall be modified for proper clearance to extend past the rear compartments. The exhaust system shall be mounted in a horizontal configuration under the passenger's side of the cab.

4.19 Fuel Hose and Electrical Harness Protection

4.19.1 If applicable, any fuel lines or electrical harnesses below the chassis frame rails shall be protected with a fireproof sleeve designed specifically for such purpose.

4.20 Chassis Air Intake Ember Guard

4.20.1 The chassis air intake shall be protected by an ember guard of 18 mesh, 0.017-inch wire diameter, and a maximum mesh opening of 0.039 inches. The ember guard shall be sized to fit and located at the intake opening. The screen shall be readily accessible for inspection and maintenance. The ember guard shall maintain a minimum ½ inch separation from the air filter.

4.21 Cabin Air Ember Guard

4.21.1 The cabin air filter shall be protected by an ember guard with a maximum mesh opening of

0.039 inches. The screen shall be located at the point of intake and easily accessible for inspection and maintenance.

4.22 Front Tow Hooks

4.22.1 Two heavy-duty tow hooks shall be provided at the front of the vehicle, one each side. The tow hooks shall be mounted to the chassis frame. The tow hooks shall be accessible after the front bumper brush guard installation.

4.23 Rear Tow Hooks

4.23.1 Two heavy-duty tow hooks shall be provided at the rear of the vehicle, one each side, below the rear bumper. The tow hooks shall be mounted to the chassis frame.

5 — Apparatus Body Description

5.1 General Body Construction

5.1.1 The body shall be designed for fire/rescue service operations only and shall be constructed to withstand off-road use. The body must be of sufficient design to be capable of withstanding the twisting and abnormal flexing, stresses and other occupational hazards caused by traveling on unimproved mountainous and rangeland roads. No commercially designed bodies intended for use in other vocations or applications are acceptable in quality, construction, design, or longevity.

5.2 Body Materials

5.2.1 The apparatus body shall be designed and constructed of materials consistent with current fire apparatus engineering technology and design standards.

5.2.2 All metal work shall be free of sharp edges, objects, or corners. No exceptions shall be allowed to this requirement.

5.2.3 The body design shall be fully tested with proven engineering and test techniques such as finite element analysis, stress coating, and strain gauging tests. Engineering and test techniques shall have been performed with special attention given to fatigue life and structural integrity of compartments and body support system.

5.3 Installation of Hardware

5.3.1 The installation of hardware parts such as hinges, catches, handles, or knobs shall be accomplished to avoid damaging the hardware or the mounting surface. After fabrication, all parts shall be cleaned of the following: smudges; loose, spattered, or excess welding; metal chips or fillings; or any other foreign material which might detract from the intended operation, function, or appearance of the apparatus or its equipment. This would include any particles which could loosen or become dislodged during the normal expected life of the equipment. Whenever possible, this cleaning shall take place before the parts are assembled.

5.4 Threaded Parts

5.4.1 Threaded parts or devices shall show no evidence of cross-threading, mutilation, or detrimental burrs. All screw type and rivet fasteners shall be tight to allow no relative movement between the attached parts. All bolts and screws shall not exceed the SAE torque standard established for the grade, screw, and thread type.

5.5 Apparatus Body

5.5.1 The entire apparatus body shall be an independent structure and shall be removable in its entirety without the disassembly of any compartments, flooring, or other structural components.

5.5.2 The body shall be designed to be approximately as wide as the outside wheel track on the rear axle. This will allow the apparatus to maneuver more easily in off-road environments.

The body shall be approximately 95 inches wide from side to side at the rear of the apparatus.

5.5.3 Each compartment shall have ¾-inch drain located in the rear of the compartment fitted with an easily removable rubber grommet closure.

5.5.4 The top of the apparatus shall have a nonskid surface across the top of both side compartments and the doors over the pump area. Additionally, it shall support, without distortion, a walking person weighing up to 300 pounds.

5.6 Body Mounting

5.6.1 A spring loaded or rubber body mounting system shall be used to mount the body to the chassis. This system shall be designed to allow independent movement between the body frame and the chassis frame protecting the module from the stresses and twisting rendered by the flexing of the chassis frame. As such, the body frame shall not rest on the chassis frame at any point. The mounts shall be pre-engineered for their intended use.

5.6.2 All of the mounting hardware (nuts, bolts, washers) required for complete body installation shall be Grade 8 for sizes ½-inch and smaller, and Grade 5 for sizes larger than ½-inch. All nuts shall be self-locking style. All mounting brackets shall be painted black.

5.7 Vertical Surfaces

5.7.1 The entire vertical surfaces at the front and rear bulkhead of the body shall be covered with a tread plate for appearance, wear, and enhanced visibility at night. The tread plate shall be designed so that joints are minimized and shall cover the entire vertical surface area. The tread plate shall also incorporate protection of the outboard corners and serve as corner scuff guards.

5.8 Grab Handles

5.8.1 Three NFPA-compliant chrome-plated grab handles shall be provided and located at the rear of the body: one mounted vertically on the rear-facing surface of the upper compartment, driver's side, outboard edge, and two 24-inch-long handles mounted horizontally on top of each of the upper compartments, parallel to the outboard edges of the body.

5.9 Rear Steps

5.9.1 Three NFPA-compliant fold-down steps shall be provided and installed at the rear of the apparatus on the left side of the body. The steps shall be fabricated from heavy duty cast aluminum with spring assisted folded hinges. The top of the steps shall be an integral diamond point skid resistant surface that allows water to flow off the step without ice formation in cold weather use. The steps shall be offset bilaterally from each other approximately 12 inches to facilitate ease of climbing. The vertical distance from the bumper to the first step, between the three steps and from the top step to the top of the apparatus shall not exceed 14 inches.

5.9.2 One warning plate shall be affixed to the rear of the apparatus body in a conspicuous location. The warning plate shall read “WARNING: DO NOT RIDE ON REAR STEP WHILE

VEHICLE IS IN MOTION. DEATH OR SERIOUS INJURY MAY RESULT.”

5.10 Compartmentation

5.10.1 All compartment interiors shall be free of exposed electrical harnesses or plumbing components. All compartments shall be as large as possible, as determined by the design of the apparatus.

5.11 Compartment Configuration

5.11.1 Compartments shall be configured as designated below:

5.12 Driver's Side Compartments

5.12.1 The driver's side lower module of the apparatus body shall have approximate overall dimensions as specified. It shall consist of three compartments, each with specified approximate clear depth behind the door when the door is shut. Each compartment shall have a “flow through” vent provided to supply air flow and minimize moisture unless designated as fuel storage.

Description Nominal Dimension

Lower module dimension ± 0.25 inches 108 inches wide by 20 inches deep

Clear depth ± 0.25 inches 18 inches

5.12.2 The three compartments are as follows:

5.12.2.1 One rescue style compartment shall be provided forward of the rear wheels, with approximate inside dimensions as specified. The door shall be vertically hinged and shall have an approximate clear door opening as specified.

Description Nominal Dimension

Compartment dimension ± 0.25 inches 35 ½ inches wide by 39 inches high by 20 inches deep

Clear door opening ± 0.25 inches 26 inches wide by 36 inches high

5.12.2.2 One compartment shall be provided center above the rear wheels, with approximate inside dimensions as specified. The door shall be a horizontally hinged, drop-down door, and have an approximate clear door opening as specified.

Description Nominal Dimension

Compartment dimension ± 0.25 inches 47 inches wide by 19 inches high by 20 inches deep

Clear door opening ± 0.25 inches 43 inches wide by 14 inches high

5.12.2.3 One compartment shall be provided aft of the rear wheels, with approximate inside dimensions as specified. The door shall be vertically hinged and shall have an approximate clear door opening as specified.

Description Nominal Dimension

Compartment dimension ± 0.25 inches 23 ½ inches wide by 39 inches high by 20 inches deep

Clear door opening ± 0.25 inches 20 inches wide by 36 inches high

5.12.3 The driver's side upper module of the apparatus body shall have approximate overall dimensions as specified. It shall consist of two separately sealed compartments and shall be installed above the center and aft compartments of the lower module. The fit and trim of the upper module shall be integral with the lower compartments in both aesthetics and function. The body module shall have two doors, horizontally hinged, and of overhead lift-up design. The forward compartment shall be designed for hose storage, with approximate minimum clear door opening as specified. The aft compartment shall be individually vented and designed for drip torch storage. There shall be a raised stainless-steel or aluminum bottom tray with integral brackets for holding two drip torches and shall extend the full length of the compartment. The tray shall have a drain tube with a drip loop to prevent vapor ignition. The aft door shall have an approximate minimum clear door opening as specified. This body module may be a separate assembly or may be integrated with the lower compartments. Diamond plate will be installed on the outside, rear face of this compartment.

Description Nominal Dimension

Upper Module Dimension ± 0.25 inches 80 inches wide by 20 inches high by 20 inches deep

Forward Compartment Clear Door Opening ± 0.25

48 inches wide by 16 inches high

Aft Compartment Clear Door Opening 22 inches wide by 16 inches high

5.13 Passenger's Side Compartments

5.13.1 The passenger's side lower module of the apparatus body shall have approximate overall dimensions as specified. It shall consist of three compartments, each with specified approximate clear depth behind the door when the door is shut. Each compartment shall have a “flow through” vent provided to supply air flow and minimize moisture.

Description Nominal Dimension

Lower Module Dimension ± 0.25 inches 108 inches wide by 20 inches deep

Clear Depth ± 0.25 inches 18 inches

5.13.2 The three compartments are as follows:

5.13.2.1 One rescue style compartment shall be provided forward of the rear wheels, with approximate inside dimensions as specified. The door shall be vertically hinged and shall have an approximate clear door opening as specified.

Description Nominal Dimension

Compartment dimension ± 0.25 inches 35 ½ inches wide by 39 inches high by 20 inches deep

Clear door opening ± 0.25 inches 26 inches wide by 36 inches high

5.13.2.2 One compartment shall be provided above the rear wheels, with approximate inside dimensions as specified. The passenger's side door shall be a horizontally hinged, drop-down door, and have an approximate clear door opening as specified.

Description Nominal Dimension

Compartment Dimension ± 0.25 inches 72 inches wide by 22 inches high by 20 inches deep

Clear Door Opening ± 0.25 inches 66 inches wide by 18 inches high

5.13.2.3 One compartment shall be provided aft of the rear wheels, below the upper horizontal compartment, with approximate inside dimensions as specified. The door shall be vertically hinged and shall have a clear door opening as specified.

Description Nominal Dimension

Compartment Dimension ± 0.25 inches 26 inches wide by 17 inches high by 20 inches deep

5.13.3 The passenger's side upper module of the apparatus body shall have approximate overall dimensions as specified. It shall consist of one compartment installed above the center and aft compartments of the lower module. The fit and trim of the upper module shall be integral with the lower compartments in both aesthetics and function. Two horizontally hinged, overhead lift- up compartment doors shall be located on the passenger's side. Each shall have an approximate minimum clear door opening as specified. This body module may be a separate assembly or may be integrated with the lower compartments.

Description Nominal Dimension

Upper Module Dimension ± 0.25 inches 80 inches wide by 20 inches high by 20 inches deep

Passenger Side Door Opening ± 0.25 inches

35 inches wide by 16 inches high

5.14 Storage of Flammable Materials Warning

5.14.1 A warning label, stating: “DANGER – Do Not Store Flammable Liquid or Combustible Material in this Compartment,” shall be provided on the exterior surface of the passenger side lower aft compartment door.

5.15 Compartment Doors

5.15.1 All compartment doors shall be integral in design and recessed into the apparatus body side, sized to provide easy access to all interior areas of the compartment. All doors shall be consistent in fit and finish with the apparatus body. All doors shall be weatherproof and maintain contact with all points of the weather stripping. Weather stripping shall be bulb type, attached to the opening flange of the compartment opening. A drip rail shall be provided to channel rain away from the lower horizontal hinged compartment.

5.15.2 Red/white reflector DOT striping shall be installed on the interior surface of all vertically hinged doors.

5.16 Door Latches and Hardware

5.16.1 Unless where noted, all compartment door latch assemblies shall be installed with threaded fasteners, shall not be welded, and shall be easily removable for servicing or replacement.

All latches shall be of a slam-type design, with a single-point latching operation. Matching striker bolts shall be utilized with all latch assemblies. All striker bolts shall have slotted mounting holes and shall be attached with bolts to captive steel plates in the body structure for strength and ease of adjustment. Welded striker bolts or plates shall not be acceptable.

5.16.2 All hardware shall be corrosion resistant and suitable for its intended use. All nuts and bolts shall be stainless steel. Stainless steel nuts shall be the self-locking type. All latch assemblies shall be keyed alike to 1250. All compartment locks for a given engine shall be either vertical or horizontal when locked so that it is visually apparent whether a compartment is locked or unlocked. Ten spare keys shall be provided.

5.16.3 Black rubber fenders shall be mount around the wheel opening to protect body sides from road debris thrown by the rear tires.

5.17 Door Hold Open Devices

5.17.1 All vertically hinged, outward-opening compartment doors shall be provided with an over center door check to hold the door in the desired position. The door check shall be attached to the top of the door and fastened to a stainless-steel plate bolted into the body and door.

5.17.2 All vertically hinged, outward opening compartment doors shall be capable of being closed with one hand, allowing a free hand to hold equipment or supplies.

5.17.3 All horizontally hinged, drop-down, outward-opening compartment doors shall open to a 90-degree angle. They shall be supported by a minimum of 3/32-inch aircraft-type stainless steel cable with stainless steel fork ends. The fork ends shall be attached at each end to a stainless bracket so that the cable can hinge as the door is closed.

5.17.4 All horizontally hinged, overhead lift-up, outward opening compartment doors shall be provided with two extending, gas cylinder type hold open devices, one mounted vertically on each side of the compartment door opening. The pressure rating of the gas cylinders shall be carefully matched to the size and weight of the compartment door and shall hold the compartment door securely open to a greater than 90-degree angle without additional support. The gas cylinder hold openers shall dampen the upward movement of the compartment door while opening and shall permit the closing of the compartment door without the need to release any type of manual locking devices.

5.17.5 All horizontally hinged, overhead lift-up compartment doors shall be capable of being closed with one hand, allowing a free hand to hold equipment or supplies.

5.18 Adjustable Shelf Channels

5.18.1 Vertically mounted aluminum Unistrut™ or composite channels shall be provided and installed in all enclosed body compartments, except passenger's side lower rear compartment, for the current or future installation of infinitely adjustable shelving, slide out trays or equipment brackets.

5.19 Compartment Shelves

5.19.1 Eight adjustable shelves shall be provided and installed in the completed body compartments. The shelves shall be 15 inches in depth and be constructed of fiberglass or aluminum and be capable of supporting 250 pounds of live load without being damaged or permanently distorted.

5.19.2 The shelf locations shall be as follows:

5.19.2.1 Two in the driver's side compartment forward of the rear wheels.

5.19.2.2 One in the driver's side center compartment. This shelf shall have a reduced height leading edge to facilitate equipment access in a raised position.