Section 1 – General Specifications The Contractor must conduct a weight study of the Truck with simulated weight on the body, including all components to ensure proper weight and weight distribution across the vehicle truck chassis axles with emphasis on the front axle. This will include the full weight of fuel/paint/water/tools (guns)/stencils and two employees. (approximately two hundred (200) lb each) Documentation showing the results of the weight study must be inserted in a clear plastic sheet protector and placed in the Truck cab at the time of delivery. A copy of the weight study must be provided to ITD for review and approval prior to starting the manufacturing process on the Truck; The Contractor must have the completed Truck weighed via certified public scale. The weight certificate must display each individual weight for the front axle, rear axle, and the combined total weight of both axles as measured in pounds. The axle weight certificate must be inserted in a clear plastic sheet protector and placed in each Truck cab at the time of delivery; The Contractor must perform a two (2) axle center thrust alignment on completed Truck after installation of the flatbed and all components. Any deficiencies in the alignment must be corrected before delivery of Truck to ITD. The wheel alignment must be performed by a vendor normally engaged in performing tire repair and wheel alignment on platform/service type truck. Documentation stating the before and after alignment settings must be inserted in a clear plastic sheet protector and placed in each Truck cab at the time of delivery. Contractor will be one hundred (100)% responsible for premature tire wear and; All welds must meet the American Welding Society www.aws.org (AWS) D1.1-96 specifications. All Joints and seems must be closed with full seam welding. Truck will be rejected for any inferior welding, and/or weld splatter. No exceptions. SECTION 2 Paint The Truck must be clean, prime coated, and powder coated per the paint manufacturer’s process for the application. The prime coat(s) and powder coat(s) must be a minimum dry thickness of 4 mils total. The powder coat must be ultraviolet resistant. The Truck must be smooth and free of rust, runs, overspray, peeling, weld splatter, and other defects; Undercoating – Manufacturer’s standard polyurethane automotive type and; Deck Surface – All walk areas shall have a hot sprayed non-slip polyurethane surface. Thickness, one hundred twenty-five (125) mils. Color is black. (Cold or roll-on system is not acceptable Surface to be sprayed prior to installing any components. All holes in deck must be drilled, as well as all welding must be complete before applying urethane. Electrical Installation All installed electrical cabling must be of adequate size to handle the anticipated loads of all electrical components. All cabling must be uninterrupted and complete with no splices; All electrical cabling must be color-coded and numbered; All cable terminal ends must be: crimped, soldered to the cables and sealed with polyolefin heat shrink tubing, or weatherproof connectors. Scotch-Loc fasteners and/or crimp butt connectors are not acceptable for any connection; All electrical cable connections must be protected with dielectric grease; The edges of all holes through which electrical cabling passes must be protected with a grommet; All electrical cabling to lamps must be stress relieved within six (6) in of the lamp; Low current circuits must be controlled by the Truck chassis’ electrical accessory power supply; All wiring used in and around the Truck cab must be automotive cross link wiring meeting Society of Automotive Engineers (SAE) specification [1128 or 1127] for under the hood temperatures and abrasion resistance. All electrical modifications and additions require the use of continuously numbered or same colored wiring and the same wire gauges (size) as the manufacturer’s wiring; All exposed wiring that is soldered must be sealed with polyolefin heat shrink tubing. Crimp- on connections are not acceptable; Exposed terminal connections must be coated with Permatex SA-9 battery protector and sealer; Original equipment manufacturers (original equipment) upfitter switches must be utilized as master switches for all electrical accessories. A label must be made and affixed near switches confirming operation of each switch; All warning lights will have trigger wire capped and left visible for future light settings and; An electrical schematic must be provided to ITD during the pre-build conference. Fasteners All threaded fastener components (bolts, washers, nuts) with a diameter designation greater than or equal to SAE one half (1/2) in must be grade eight (8) composition. Nuts must be all metal self-locking, lock washers are not acceptable. Two (2) bolt threads must extend through all nuts when fasteners are applied and properly tightened/torqued. All components must have grade identifier marks and a registered manufacturer’s logo. All bolts and nuts must be zinc plated.
