Workmanship Standards~4.docx

WORKMANSHIP STANDARDS: 06/2021

All work must be done in accordance with all of ODOT quality and workmanship standards that are described in this section. Note: Not all will be applicable to every job.

3.Y.1 TECHNICAL DEFINITIONS:

3.Y.1.1 "AMP" means ampere (a measurement of current).

3.Y.1.2 "AWG" means American Wire Guide.

3.Y.1.3 "EPA" means Environmental Protection Agency.

3.Y.1.4 "ºF" means degrees Fahrenheit (measure of temperature).

3.Y.1.5 "FMVSS" means Federal Motor Vehicle Safety Standards.

3.Y 1.6 “FOPS” means Falling Object Protective Structure.

3.Y.1.7 “Heavy Duty” means the component exceeds the usual quantity, quality, or capacity of that supplied with a standard production Unit.

3.Y.1.8 "HP" means horse power.

3.Y.1.9 "ISO" means International Organization of Standardization.

3.Y.1.10 "LB" means pound.

3.Y.1.11 "MHz" means megahertz (radio frequency unit).

3.Y.1.12 "MPC" means Manufacturing Process Conference.

3.Y.1.13 "MPH" means miles per hour.

3.Y.1.14 “MSHA” means Mine Safety and Health Administration 3.Y.1.15 "OEM" means Original Equipment Manufacturer.

3.Y.1.16 “OSHA” means Occupational Safety & Health Administration 3.Y.1.17 "PREVENTIVE MAINTENANCE" means maintenance recommended or required by the manufacturer in order to ensure proper performance of the Unit and to satisfy the terms and conditions of warranty coverage.

3.Y.1.18 "PTO" means power take off.

3.Y.1.19 “ROPS” means Rollover Protective Structure.

3.Y.1.20 "RPM" means revolutions per minute.

3.Y.1.21 "SAE" means Society of Automotive Engineers.

3.Y.1.22 "SINAD" means Signal plus noise plus distortion to noise plus distortion ratio.

3.Y.2 GENERAL PROVISIONS:

3.Y.2.1 SILENCE OF SPECIFICATIONS: The apparent silence of the Specifications as to any detail, or the apparent omission of a detailed description concerning any point, shall be regarded as meaning that only the best commercial practice is to prevail and that only materials and workmanship of first quality are to be used. The bidder shall provide all components, hardware, fluids and parts necessary for proper assembly, installation, and operation of the Units, even though certain items may not be specifically described in this bid opportunity. This includes all cables, fittings, couplers, brackets, and adapters, etc. Quote pricing must include the cost of such components, hardware and parts.

However, if any omitted Specification results in ambiguity as to material characteristics of the Bid item, or component incompatibility may affect required performance capabilities of a Bid item, and (a) inclusion of a Specification is necessary to enable a reasonable Bidder in the particular industry to properly identify material characteristics, or (b) a reasonable Bidder in the particular industry would recognize component incompatibility, Bidder shall submit a formal request for change as set forth in the ITB. Failure to make such a request is at Bidder's risk, and the Bidder awarded a Contract shall be required to provide Goods meeting ODOT's needs with regard to any omitted Specification or component incompatibility for which a request for change should reasonably have been sought.

3.Y.2.2 ADHERENCE TO THE SPECIFICATIONS: Deviations from any of the Specifications may result in Bid rejection. In the event ODOT determines that a deviation results in quality or characteristics that are equivalent or superior to that required in the Specification, ODOT may consider the deviation to be responsive. However, it is within ODOT's sole discretion to reject the Bid as non-responsive regardless of equivalence or superiority, and Bidder assumes the risk that its deviation shall render the Bid non-responsive. Deviations unacceptable to ODOT that are discovered after delivery shall be corrected at no cost to ODOT.

3.Y.2.3 DRAWINGS:

3.Y.2.3.1 INCLUDED IN THE ITB: The purpose of drawings, if included in the ITB, is to clarify the intent of the Specifications. Bidder is cautioned that drawings may NOT be relied upon, and may NOT reflect complete or accurate information contained in the Specifications, including all material requirements. Bidder is also cautioned that if there is a conflict between the drawings and the Specifications, the Specifications shall take precedence over the drawings.

3.Y.2.3.2 REQUIRED OF BIDDER: Should the Bidder be required to provide drawings, Bidder must submit them with its Bid with title block.

3.Y.2.3.3 PRODUCTION DRAWINGS: If applicable, Contractor must submit production drawings prior to fabrication of unit.

3.Y.2.4 STANDARD COMPONENTS: Unless stipulated otherwise elsewhere in the ITB, Goods shall include all components and accessories listed by the manufacturer as standard.

3.Y.2.5 COMPONENT SELECTION: The components selected shall be rated for the maximum loading they would be subjected to in severe service environments. The torque rating of a driven component shall exceed the input torque. The component parts and structure of the Unit shall be sized and designed to safely withstand the maximum load imposed, without inducing failure or deterioration. All Units shall be constructed from current production components as listed in current manufacturer parts catalogs.

3.Y.2.6 NECESSARY COMPONENTS: The Bidder awarded a Contract shall provide all components, hardware, and parts necessary for proper assembly, installation, and operation of the Unit, even though certain items may not be specifically described in the ITB Specifications. This includes all cables, fittings, couplers, brackets, adapters, etc. Bidder shall include the cost of such components, hardware and parts in the Bid price.

3.Y.2.7 REFERENCED STANDARDS: Certain ISO, SAE, and other consensus standards are referenced in these Specifications. Unless otherwise specified elsewhere in the ITB/RFP or required by law, the current version of each standard at time of delivery shall apply to the Unit and components thereof.

3.Y.3 DEFAULT TECHNICAL SPECIFICATIONS: Unless particular Specifications in ITB or the Special Contract Terms and Conditions require otherwise, the following default Specifications shall apply.

3.Y.3.1 LABELS: All controls and instrumentation shall be clearly identified and/or permanently labeled. Labels shall be engraved plastic, stainless steel, or aluminum alloy. Decal labels shall be printed on waterproof printable vinyl or film using waterproof UV resistant ink, Eco Solvent ink or equal. The decal shall have a waterproof UV over laminate exterior. Labels shall be permanently affixed.

3.Y.3.2 ADVERTISING: Advertising is not allowed, except for the standard manufacturer's markings typically on a Unit. A Contractor identification sticker not to exceed four (4) inches by six (6) inches may be applied.

3.Y.3.3 MUD FLAPS: Mud flaps must be black with no legends.

3.Y.3.4 SERVICE AND INSPECTION POINTS: The Unit shall be designed so that inspection and/or service points shall be readily accessible, including grease fittings and tire valve stems, drain ports, etc.

3.Y.3.5 COVERS: All caps and covers that must be removed in order to perform daily to bi-weekly Preventive Maintenance, other scheduled warranty service, or maintenance recommended or required by the Contractor, must be secured to the Unit by a chain or other device. All hoses, pipes, and plumbing connections shall have either retained covers, quick disconnects, or protective caps.

3.Y.3.6 SPECIAL TOOLS: If special tools, gauges, adapters, etc., are required for maintenance, adjustment and/or inspection of the Unit or a component thereof, they shall be identified and delivered with the Unit. This includes the latest version of diagnostic software, where applicable.

3.Y.3.7 FILTERS: Filters shall be easily accessible and replaceable without removing or disconnecting other components. If necessary, filters shall be remotely mounted to meet this requirement. Spin-on or cartridge filters are required for fluid service. All filters shall be heavy-duty and sized for severe service environments. Filter housings, including engine air cleaner housings, shall be manufacturer’s standard material.

3.Y.3.8 BOLTS AND NUTS: Bolts shall be used with nuts and washers of identical grade. Bolt and nut grade certification may be required. Grade eight (8) bolts shall be medium carbon alloy steel. Grade eight (8) bolts of boron steel or grain enhanced steel are unacceptable.

3.Y.3.9 HOSE, WIRE AND TUBE ROUTING: Hose, wire and tube routing shall not impede normal maintenance and adjustment of the Unit. Hoses, wires and tubes shall be securely and neatly positioned. Kinks in hoses, wires, and/or tubing are not acceptable. See also SECTIONS 3.Y.3.11, 3.Y.3.13 and 3.Y.3.17.

3.Y.3.10 FLUIDS AND LUBRICANTS:

3.Y.3.10.1 Unless otherwise specified elsewhere in the ITB, fluids and lubricants shall be compatible with the following:

3.Y.3.10.1(a) Engine Oil – OEM Specifications Standards

3.Y.3.10.1(b) Hydraulic Fluid - AW ISO 32

3.Y.3.10.1(c) Grease - Chevron Ultra Duty II, Grade 2

3.Y.3.10.2 Engine coolant shall be OEM manufacturers recommended anti-freeze coolant. The coolant system shall have a coolant overflow recovery system with an easily visible means of checking the fluid level without removing any parts.

3.Y.3.10.3 Remote grease line(s) shall be flushed / purged prior to connection to bearing(s).

3.Y.3.11 HYDRAULIC SYSTEMS: (Workmanship Standards applicable to both traction and controls systems):

3.Y.3.11.1 Components containing hydraulic fluid shall not be installed in the cab.

3.Y.3.11.2 Hydraulic Symbols: Hydraulic symbols on schematics shall be interpreted per American National Standard Institute (ANSI) Y32.10.

3.Y.3.11.3 Leaks: Hydraulic leaks are not acceptable. A leak is defined as any fluid flow larger than one (1) drop in four (4) hours.

3.Y.3.11.4 All components installed in the hydraulic system shall be free of contamination and shall be flushed out or cleaned, if necessary, to meet this requirement. Components containing hydraulic fluid shall not be installed in the cab.

3.Y.3.11.5 Hose Routing: Hose routing shall meet the following requirements:

3.Y.3.11.5(a) The bend radii of hoses shall be not less than the manufacturers' recommended minimums.

3.Y.3.11.5(b) Hoses shall be routed no closer than six (6”) inches from exhaust components or other heat sources unless proper shielding is provided.

3.Y.3.11.5(c) Hoses shall not come in contact with moving parts.

3.Y.3.11.5(d) Hoses shall be clamped to supporting structures at intervals not exceeding sixty (60) hose diameters. Clamps shall be polypropylene cushion clamps.

3.Y.3.11.5(e) Black wire ties securing hoses shall be used for ultraviolet stability.

3.Y.3.11.5(f) Fittings shall be steel thirty-seven-degree (37º) flare type on all pressure lines where practical. Flat-faced "O" ring seal type fittings are acceptable.

3.Y.3.11.5(g) Hoses shall not be routed through holes or across sharp edges without protection from being chafed or cut.

3.Y.3.11.5(h) Hoses shall be of sufficient length to prevent stretching, distortion, and disconnecting.

3.Y.3.11.6 Pipe fittings shall not be used on the pressure side of any hydraulic circuit. A Teflon sealant shall be used on pipe threads. Sealant shall be used sparingly and shall not contaminate the hydraulic system.

3.Y.3.11.7 All hoses on the pressure side of a circuit shall conform to SAE 100R2 Type AT and/or SAE100R16. Hoses on the suction side of the hydraulic system shall be rated for suction service.

3.Y.3.11. All hydraulic components shall be rated for working pressures to exceed system operating pressures, and have a minimum burst of one and a half (1-1/2) times the system operating pressure.

3.Y.3.11.9 All hydraulic quick disconnects shall be stainless steel and equipped with protective covers that are retained by the coupling with a chain, wire cable or similar device. Parker 60 series ISO 7241, series B, Dixon DQC H-series ISO-B or approved equal shall be used.

3.Y.3.12 ELECTROMAGNETICS

3.Y.3.12.1 Electromagnetic disturbances generated by on-board devices to radio receivers installed on the unit shall not exceed the values in Table five (5) of SAE Standard J551/4.

3.Y.3.12.2 No system or component on the unit shall be adversely affected by on-board or external electromagnetic emissions of the types and intensities defined in SAE Standards J551/1, J551/11, and J551/12.

3.Y.3.12.3 No system or component, electrical, hydraulic, or mechanical shall be adversely affected by calendrical transitions.

3.Y.3.12.4 The receiver of a two (2)-way radio (installed and operating at 26.0 to 28.0 MHz, 30.86 to 47.66 MHz, 150.0 to 460.0 MHz or 750.0 to 900.0 MHz) shall not be degraded more than 3dB by interference generated from electrical components supplied with the vehicle. (Degradation shall be measured at the radio's specified 12dB SINAD point.) The responsibility for curing any interference is on the manufacturer or the contractor to solve the interference. The ISB Wireless group will be available to help with troubleshooting and identifying interference. It is solely up to the manufacturer or contractor to provide and implement the cure.

3.Y.3.12.5 All vehicle operating characteristics and components shall not be affected by on-board two-way radio communications equipment transmitting at the frequencies and power levels of 26.0 to 28.0 MHz at 6 watts, 47.0 to 47.2 MHz at 100 watts, 150.0 to 160.0 MHz at 100 watts and 750.0 to 900.0 MHz at 100 watts.

3.Y.3.12.6 Below is IF frequency information on the Harris radio used by ODOT/OSP:

Mixers U130 and U131 are double balanced mixers. U131 is used for the VHF band mixing 136-174 MHz to an IF of 21.4 MHz. Frequencies 136-157.5 MHz use high side mixer injection with an LO range of 157.4-178.9 MHz. 157.5-174 MHz use low side mixer injection with an LO range of 136.1-152.6 MHz. In VHF operation, the receiver uses different mixer injection sides. U93 and U136 RF switch ICs route the VHF receive signal to a high pass or low pass filter network for low and high side injection, respectively. U135 and U136 provide RF switching of the desired receive band to couple into the mixers. Mixer U130 is used for UHF/700/800 bands mixing 380-520 MHz and 762-870 MHz to an IF of 156.525 MHz. The UHF band uses high side mixer injection with an LO range of 536.525-676.525 MHz. The 700/800 bands use low side mixer injection with an LO range of 605.475-713.475 MHz.

3.Y.3.12.7 When specifications require units to be pre-wired for state installed two-way radio use the following:

a. 2-way Radio Wiring Circuits: A wiring “loom” shall be provided to meet the following requirements and must have at least 24 inches of available wire and be labeled “radio circuits”. This will be routed out from under dash/console and coiled on cab floor. Wire ends shall be “capped” to prevent short circuiting.

(a.1) 1, 10 gauge red wire +12V, connected to the vehicle’s positive battery terminal, battery disconnect switch or adequately sized 24/12 volt inverter. A 30 amp circuit breaker or fuse (that matches units OEM style) shall protect this circuit.

(a.2) 1, 10 gauge black wire -12V, connected to the vehicle’s negative battery terminal or OEM dedicated chassis ground point.

(a.3) 1, 14 gauge yellow wire to provide +12V with the ignition switch in the “on” and “accessory” position. A 3 amp circuit breaker or fuse (that matches units OEM style) shall protect this circuit.

(a.4) 1, 14 gauge red wire +12V, connected to the vehicle’s positive battery terminal, battery disconnect switch or adequately sized 24/12 volt inverter. A 5 amp circuit breaker or fuse (that matches units OEM style) shall protect this circuit.

(a.5) 1, 14 gauge black wire -12V, connected to the vehicle’s negative battery terminal or OEM dedicated chassis ground point.

3.Y.3.13 ELECTRICAL WORKMANSHIP AND MATERIALS:

3.Y.3.13.1 All wire shall be un-tinned stranded copper with cross-linked polyethylene insulation. Minimum wire size for vendor installed terminal to terminal wiring shall be fourteen (14) AWG unless provided as a stock factory component or approved by ODOT fleet operations. Wire runs will be adequately sized for distance and component amperage draw. Wires shall be color coded. Dyes shall not be used for color coding. Wire runs and color coding shall be continuous and terminate within a weatherproof junction box.

3.Y.3.13.2 Unless otherwise specified elsewhere in the ITB/RFP, except for multi-terminal connectors (Weather Pack, Delphi/Packard, Deutsch, etc.), solderless terminals shall be used for all connections. If connections must be soldered, solder shall be 60-40 tin-lead alloy with a single or multiple rosin cores. No cold joints or air pockets shall be acceptable. A maximum 25 watt iron shall be used. No solder shall wick up under the wire insulation. Both the wire and the terminal shall be tinned before soldering.

3.Y.3.13.3 All ring terminals on ten (10) AWG and smaller wires shall be insulated.

3.Y.3.13.4 Insulated ring terminals shall meet SAE AS7928 Class 1 and Class 2 requirements. SAE AS7928 ring terminals have an extra copper sleeve around the terminal barrel that improves the holding force and reduces corrosion. Ring terminals shall be crimped with an AMP model 58433-3 ratchet crimper or equal ratchet crimper. If a specially- fabricated ratchet crimper is utilized, the Contractor shall submit a description of the intended crimping tool at ODOT's request.

3.Y.3.13.4(a) Soldered ring terminals shall fulfill the requirements stated herein as follows: Soldered ring terminals shall be soldered with 60-40 tin-lead alloy with a single or multiple rosin core. No cold joints or air pockets shall be acceptable. A maximum 25 watt iron shall be used. No solder shall wick up under the wire insulation. Both the wire and the terminal shall be tinned before soldering.

3.Y.3.13.5 Butt splices shall have moisture barriers and integral polyolefin heat shrinkable sleeves. Heat shrink tubing over non-sealed butt splices is not acceptable. Butt splices shall be crimped with an AMP model 55893-1 or equal ratchet crimper. If a specially-fabricated ratchet crimper is utilized, the Contractor shall submit a description of the intended crimping tool at ODOT's request.

3.Y.3.13.6 No FASTON type or spade terminals shall be used unless an integral part of pre-manufactured electrical component.

3.Y.3.13.7 Insulation-piercing connectors (Scotch Locks type) shall not be used.

3.Y.3.13.8 Wires shall be protected by looms, sleeving and grommets. Wire bundles shall be routed away from moving parts and hot components. Wires and bundles shall be clamped at intervals of not greater than twenty (20) inches with cushioned metal Adel type clamps.

3.Y.3.13.9 Plastic wire ties shall be black ultraviolet-protected. Wire ties shall be applied with a Panduit GS2B or equal controlled-tension installation tool. If a specially-fabricated controlled-tension installation tool is utilized, the Contractor shall submit a description of the intended controlled-tension installation tool at ODOT's request.

3.Y.3.13.10 All chassis/body combination units shall have a separate grounding strap installed from the body to the chassis.

3.Y.3.13.11 Wire Routing: Wire routing shall ensure that the following requirements are met:

3.Y.3.13.11(a) Wiring shall not be exposed to throw-offs from tires.

3.Y.3.13.11(b) Wires shall not be routed closer than six (6”) inches to exhaust components or other heat sources, unless they are shielded.

3.Y.3.13.11(c) Wires shall not come in contact with moving parts.

3.Y.3.13.11(d) Wire runs that could be subjected to ice and snow buildup require additional clamping, supports or protection.

3.Y.3.13.11(e) Wires and wire harnesses shall not be routed through holes or across sharp edges without protection from being chafed or cut.

3.Y.3.13.11(f) Wires and wire harnesses shall be routed as far away from any air bag location as practical, and/or per OEM specifications, so not to interfere with air bag deployment.

3.Y.3.13.11(g) Routing of wires and wire harnesses for any additional components and/or accessories must not interfere with any OEM sensors, switches and/or safety equipment. Refer to the OEM body builders manuals before installation.

3.Y.3.13.12 All added equipment and switches shall be deactivated by the ignition switch, except for those items required by law to be active.

3.Y.3.13.13 Wire runs and color shall be continuous and terminate at weather proof junction boxes.

3.Y.3.13.14 Positive (hot), electrical points including ring poles and power rails shall be boxed in, covered, or otherwise protected to prevent accidental short and/or overload from incidental contact. Only OEM approved power source connection points are allowed.

3.Y.3.13.15 Use of any flame on any heat shrinking insulation tubing or wire harness protection is not allowed.

3.Y.3.13.16 Use of any insulation-piercing meter leads is not allowed. Meter leads used in “back probing” any connector must be correctly sized to prevent damage to the connector.

3.Y.3.14 ON BOARD DIAGNOSTICS: If available from the manufacturer, all units shall be equipped with electronic self-diagnostic systems.

3.Y.3.15 COLOR AND FINISH:

3.Y.3.15.1 The Unit shall be painted as specified in the ITB. No additional stripes or styling enhancements are permitted.

3.Y.3.15.2 Sharp corners and Edges: Cut metals and other materials shall have rounded corners and edges to prevent injury to personnel.

3.Y.3.15.3 Surface Preparation: All welding slag and scale shall be removed and surfaces shall be clean and free of dirt and grease prior to painting.

3.Y.3.15.4 Paint application to be in an OSHA approved facility. Painting of metal surfaces shall conform to best industry practices and shall provide a well- bonded surface of paint. Orange peel and runs are not acceptable. No metals shall be left bare. ID plates, tags, part numbers, serial numbers, etc. shall not be painted.

3.Y.3.15.5 All paint shall be lead free.

3.Y.3.16 GENERAL WELDING REQUIREMENTS:

3.Y.3.16.1 Distortion of assembled parts is not acceptable. All welds shall have proper penetration and be relatively uniform in appearance. All welds shall provide a metal-to-metal bond, with adequate penetration using proper flux and/or welding materials. Downhill welds are not acceptable for ten (10) gauge or thicker material, unless unavoidable using best industry practices. If downhill welds are used, they shall have proper penetration.

3.Y.3.16.2 Some characteristics of an unacceptable weld are the following:

3.Y.3.16.3 Body Fillers: The covering of welds with body fillers, seam sealers or similar practice is not acceptable.

3.Y.3.17 AIR SYSTEMS:

3.Y.3.17.1 Leaks: Air leaks are not acceptable.

3.Y.3.17.2 Air lines: All air lines shall be DOT air brake lines or approved equal.

3.Y.3.17.3 Air systems interface: The air system interface with air brake systems shall have appropriate isolation valves.

3.Y.3.17.4 Hose Routing: Hose routing shall be clamped or tied to supporting structures at approximately twenty (20) inch intervals.

3.Y.3.17.5 The bend radius of air lines shall not be less than the manufacturer's recommended minimum.

3.Y.3.17.6 Air lines shall not be routed closer than six (6) inches to exhaust components or other heat sources, unless they are shielded.

3.Y.3.17.7 Air lines shall not come in contact with moving parts.

3.Y.3.17.8 Air lines shall not be routed through holes or across sharp edges without protection from being chafed or cut.

3.Y.3.17.9 Air lines routing shall be so that local low points (water traps) are minimized.

3.Y.3.17.10 Hoses shall be of sufficient length to prevent stretching, distortion, or disconnecting. Extra hose shall be neatly bundled and tied off.

3.Y.3.18 OPERATOR(s) - EQUIPMENT INTERFACE:

3.Y.3.18.1 Control Locations: The operator(s) stations(s), including safety devices, controls, gauges and visibility, shall be configured for operators with physical dimensions as specified in SAE J833 (medium build).

3.Y.3.18.2 Instrumentation Visibility: Instrumentation, gauges, warning lights, etc., shall be sized and located so they are easily read by operators with the physical dimensions specified in SAE J833 (medium build).

3.Y.3.18.3 Work Area Visibility: Visibility of the work area, road, etc., shall be unobstructed, and provide for safe equipment operation.

3.Y.3.19 ADDITIONAL COMPONENTS - EQUIPMENT INTERFACE:

3.Y.3.19.1 Mounting Locations: Installation of any additional components and/or accessories must not interfere with any OEM sensors, switches and/or safety equipment. Refer to the OEM body builders manuals before installation.