TEXAS DEPARTMENT OF TRANSPORTATION GENERAL SERVICES DIVISION

Transcription

1 TEXAS DEPARTMENT OF TRANSPORTATION GENERAL SERVICES DIVISION PREPARED BY: Gary L. Baisden, CPPB SPECIFICATION NO. FAX NO.: (512) CERTIFIED RELIFE PROGRAM ON CONSTRUCTION EQUIPMENT, RECONDITIONING OF PNEUMATIC-TIRED LOADER PUBLICATION This specification is a product of the Texas Department of Transportation (TxDOT). It is the practice of TxDOT to support other entities by making this specification available through the National Institute of Governmental Purchasing (NIGP). This specification may not be sold for profit or monetary gain. If this specification is altered in any way, the header, and any and all references to TxDOT must be removed. TxDOT does not assume nor accept any liability when this specification is used in the procurement process by any other entity. PART I GENERAL CLAUSES AND CONDITIONS 1. Parts furnished under this specification shall be original equipment manufacturer (OEM) parts or OEM approved remanufactured parts, as normally offered to commercial trade, and shall be of quality workmanship and material. The bidder represents that all parts offered under this specification shall be new or an OEM approved remanufactured part/component. 2. Bidder should submit with the bid, or have on file with TxDOT, Austin, Texas, the latest printed literature and detailed specifications on the type of reconditioning work the bidder proposes to furnish. This literature is for information purposes only. 3. The unit shall be completely disassembled, inspected, and reconditioned with new OEM or OEM approved remanufactured parts. All equipment, including standard and supplemental equipment, shall be re-installed and the unit made ready for continuous operation. 4. All parts not specifically mentioned which are necessary for the unit to be completely reconditioned and ready for operation shall be furnished by the vendor. All parts shall conform in strength, quality and workmanship to the accepted standards of the industry. 5. The unit provided shall meet or exceed all Federal and state of Texas safety, health, lighting and noise regulations and standards in effect and applicable to equipment furnished at the time of manufacture. 6. It is the intent of the TxDOT to purchase goods, equipment and services having the least adverse environmental impact, within the constraints of statutory purchasing requirements, departmental need, availability, and sound economical considerations. Suggested changes and environmental enhancements for possible inclusion in future revisions of this specification are encouraged. 7. TxDOT encourages all manufacturers to comply voluntarily with the Society of Automotive Engineers (SAE) Recommended Practice for marking of plastic parts per current SAE J1344. All plastic components furnished to this specification should have an imprinted SAE symbol identifying the resin composition of the component so that the item can be recycled after its useful life. Manufacturers are encouraged to use recycled plastics and materials in the manufacture of their products in order to conserve natural resources, energy and landfill space. Bidders should note that future specification revisions may require mandatory compliance with the SAE plastic coding system. 8. The TxDOT is committed to procuring quality goods and equipment. We encourage manufacturers to adopt the International Organization for Standardization (ISO) standards (technically equivalent to the American National Standards Institute/American Society for Quality Control (ANSI/ASQC Q )) and obtain certification. Adopting and implementing these standards is considered beneficial to the manufacturer, the TxDOT, and the environment. It is the TxDOT's position that the total quality management concepts contained within these standards can result in reduced production costs, higher quality products, and more efficient use of energy and natural resources. Manufacturers should note that future revisions to this specification may require ISO certification. 9. Measurements will be given in both the English and metric system. Where any conflict between the two stated measurements may occur, the measurements provided in the English system shall supersede those provided in the metric system. PART II SPECIFICATIONS 1. SCOPE: This specification describes the minimum repair work required to recondition a John Deere articulated frame pneumatic-tired loader under John Deere Industrial Equipment Company's Certified Relife Program. The reconditioning work shall be performed by an authorized John Deere dealer who is certified by John Deere Industrial Equipment Company to perform all phases of John Deere's Certified Relife Program on industrial equipment. The unit shall be completely reconditioned with new OEM parts or OEM approved remanufactured parts, serviced, tested and made ready for continuous operation. Units reconditioned under this specification shall meet or exceed all requirements herein. 2. DISASSEMBLY: The entire machine shall be completely disassembled. All machined components such as spindles, hubs, valve bodies, gears, gear casings, axles, clutch plates, and all other machined component shall be vatted and magnafluxed and inspected for cracks and damage. Worn, damaged or defective parts shall be replaced before the reassembly process begins. 3. FRAME: The frame shall be bead blasted to bare metal and inspected for cracks and damage. All welds shall be inspected. 1-5

2 Any welds showing signs of deterioration or cracking shall be repaired to the accepted standards of the industry. The entire frame shall be primed and painted prior to reassembly of machine Replace articulation pins and bushings Replace cab isolation mounts. 4. DIESEL ENGINE: The following repairs shall be performed to the diesel engine: 4.1. Install a new John Deere liquid-cooled diesel engine of equivalent horsepower and displacement to the original engine Recondition or replace alternator and starter. Replace battery(ies). Total ampere rating of battery(ies) shall not be less than 950 cold cranking amps (CCA) Neutral start system shall be inspected and tested. Replace worn, damaged or defective parts Inspect fuel filtration system. Replace fuel pump and filter(s) and any worn, damaged or defective parts Replace engine oil filter Inspect engine air cleaner assembly and pre-cleaner for proper engine air filtration. Replace any worn, damaged or defective component. Replace the engine air cleaner's primary element, safety element, pre-cleaner and restriction (service) indicator. Restriction (service) indicator shall be easily visible inside the operator's station Replace radiator, hoses, clamps, thermostat, radiator mounts and any other engine cooling related parts. Coolant system shall have antifreeze protection to -30 degrees F (-34 C) or lower Replace muffler, exhaust pipe, gasket, clamps and any other exhaust system related parts. Muffler and exhaust pipe shall be of sufficient length to exhaust fumes away from the operator. Exhaust pipe shall be angled at the top to prevent rain from directly entering the exhaust system Replace engine frame bushings. 5. DRIVE TRAIN: The following repairs shall be performed to the drive train: 5.1. Disassemble transmission. Replace transmission clutch and pump, clutch disc plates, seals, bushings, brake plates, filter, control cables, and transmission cover gasket Disassemble and inspect planetary final drives. Replace gears, bearing cups and cones, seals, pins, shims, and o-rings Inspect front and rear differential drive systems. Replace bearing cups and cones, piston rings, spiral bevel gear, pinion gear, disks, plates, washers, shaft, shims and seals Replace any other drive train related parts that are found to be worn, damaged or defective. 6. STEERING: Inspect steering cylinders and all related pins and bushings, repair as needed. Replace any worn or damaged parts. 7. BRAKING SYSTEM: Inspect and test the service brake and parking brake system for proper operation. All wear items such as brake disks shall be replaced. The entire brake system shall meet the current performance requirements of SAE J1473 at time of manufacture. 8. TIRES: The unit shall be equipped with new 17.5 x 25, 12-ply rating (Load Range F), type L-2, nylon-cord body construction, tires. 9. HYDRAULIC SYSTEM: The entire hydraulic system shall be drained, flushed and thoroughly cleaned of all hydraulic fluid and any metal fragments, shavings and debris. Inspect hydraulic reservoir tank and all hydraulic lines, pumps, motors, cylinders, fittings, control and shuttle valves. Replace any worn, damaged or defective parts All hydraulic cylinders shall be reconditioned and tested for proper operation. Replace pitted, bent, worn or damaged polished cylinder rods Replace hydraulic pump(s) and all suction and return hydraulic oil filters. Hydraulic filters shall be minimum 10 micron or finer rated Replace all hydraulic hoses Replace worn, damaged or defective hydraulic fittings All hydraulic hoses and lines shall be securely fastened at sufficient intervals to prevent sagging and insure clearance of mechanical parts. Routing of the hosing or lines through the sub-frame, operator's platform or the like shall be in such a manner as not to interfere with the normal operation and use or present a safety hazard. Rubber grommets shall be used wherever hydraulic hoses pass through metal. 10. ROPS CAB: The following repairs shall be performed to the roll-over protective structure (ROPS) cab: Certify ROPS meets the current performance requirements of SAE J1040 at time of manufacture Repair or replace damaged or rusted sheet metal Replace front and rear powered windshield wipers and washers Replace heater and defroster. Heater shall be minimum 40,000-BTU's. Replace heater hoses, clamps and any related valving. 2-5

3 10.5. Replace temperature rheostat and fan control Inspect inside and outside rearview mirrors. Replace worn or damaged mirrors Replace broken or cracked glass with tinted type safety glass. Film tinted glass is not acceptable Doors shall latch in the full open and closed position. Repair or replace inoperative latch mechanisms, as necessary Replace seat and seat belt. Seat shall be latest style offered by manufacturer and be cushioned, adjustable type, shock absorbing suspension or equal, with padded backrest. Seat belt shall meet the current performance requirements of SAE J386 at the time of manufacture Cab floor shall be thoroughly cleaned, primed and painted. A full width rubber mat shall be installed on the floor as normally provided by the manufacturer Inspect access steps to cab. Repair or replace worn or damaged steps. Steps shall have a non-skid type surface. Replace all slip resistant pads Environmental soundproofing material shall be installed on interior cab walls and ceiling to limit sound levels in the cab. 11. CONTROLS: All controls on the unit including bucket, transmission, brake, accelerator, differential lock, parking brake, steering and throttle shall be inspected and tested for proper operation. Replace worn or damaged parts. Install new control valve(s) and all linkage and pins. 12. INSTRUMENTATION: Replace all instrumentation gauges and electronic monitoring system. All of the items shall be easily visible to the operator Replace hourmeter. Hourmeter shall be electric quartz type, shock proof, totally sealed case, with readout up to 9,999.9 hours. Three screw or flush mount with system voltage range between 10-32V. EXAMPLE: Hobbs Model , or TxDOT approved equal Test audible alarm and warning light for the following engine conditions, repair as necessary: High engine coolant temperature Low engine oil pressure. 13. SAFETY AND SPECIAL EQUIPMENT: Repairs shall be performed on the following safety and special equipment items: Replace horn and backup alarm. Horn and backup alarm system shall be distinguishable from the surrounding noise level. Backup alarm shall meet the current requirements of SAE J994 at the time of manufacture Vandalism protection group shall be inspected for completeness. Any missing, worn, damaged or defective parts or components shall be replaced. The vandalism protection group shall include, as a minimum, locking filler caps for the fuel tank, hydraulic tank, oil supply and radiator. Filler caps located behind a locking panel(s) are acceptable in lieu of individual locking caps Cab door and engine side-panels shall be lockable All lockable panels and compartments shall be equipped with an integrated locking system, keyed alike, or padlocks. If padlocks are furnished, two brass keys per lock shall be provided. All padlocks shall be keyed alike. The padlocks furnished shall be of quality construction greater than or equal to a Master Lock # Provide straight-ahead locking bar Repair transmission bottom guard, as necessary. Provide new bottom guard if one is not installed on the unit Replace (or provide) slow moving emblem. Slow moving emblem shall be mounted base down on the rear of the unit with unobstructed view and not less than 3 feet (.9 m) nor more than 5 feet (1.5 m) above the road surface. Emblem shall not be mounted on or cover any portion of the rear radiator guard Replace any missing product safety features, shields, guards or panels. 14. ROADWAY LIGHTING: The following repairs shall be performed on the roadway lighting system: Replace front headlights with white halogen sealed-beam type lamps Replace amber flashing warning lamps Replace combination stop and tail lamps, and red reflectors mounted at the rear of the unit Replace white light at license-plate holder Replace all electrical wiring on the unit. Wiring shall be insulated and enclosed in a fibrous loom, plastic loom or flexible conduit for protection from external damage and short circuits. Wiring shall be securely fastened at sufficient intervals to prevent sagging and insure clearance of mechanical parts. Routing of the wiring through the sub-frame, operator's platform or the like shall be in such a manner as not to interfere with the normal operation and use or present a safety hazard. A sealed, splice-free modular wiring harness is acceptable. Rubber grommets shall be used wherever wire or harness pass through metal. 15. WEIGHT CENTERLINE: The weight centerline, computed with full fuel tank, scarifier and moldboard resting on road surface, without operator, shall be clearly marked on each side of the unit with a green vertical line approximately 3-inches (76 mm) 3-5

4 wide and 5-inches (127 mm) high. (This is for safe loading on trailers). 16. SAFETY PLAQUES OR DECALS: Product safety plaques or decals shall be furnished and shall be affixed at the operator's station and at any hazardous area. The safety plaques or decals shall describe the nature of the hazard, level of hazard seriousness, how to avoid the hazard, and the consequence of human interaction with the hazard. Permanent plaques are preferred to decals. Type, size and location of product safety plaques or decals shall be in accordance with the current ANSI requirements in effect at time of manufacture. A permanent lubrication plaque shall be furnished and shall be visible from the outside of the machine. The plaque shall notate all lubrication points and recommended periodic oil changes and lubrication intervals. 17. PAINTING: All components shall be primed and painted with lead free paint meeting Federal Yellow No of Federal Standard 595b except for glass, rubber and those metallic accessories or fixtures constructed of rust-resistant or plated material not normally painted. Lead paint is not acceptable. Examples of paints meeting this requirement are: Du Pont No. BN552 PPG Industries No Sherwin Williams No The interior of the cab shall be painted a non-glare, lusterless color as normally recommended and provided by the manufacturer. 18. MANUALS: One copy each of an illustrated parts book, operator's manual and service manual shall be delivered with each unit The manuals shall be as detailed as possible outlining all necessary service and operating instructions for each unit delivered. Parts list(s) shall cover all components of the machine. Each part shall be identified by part number, description and component location. Necessary warnings and product safety precautions shall be included The following additional information shall be provided by the vendor at time of delivery if it is not included in the manual(s) required above Manufacturer's recommended service preventive maintenance intervals Recommended fluids, lubricants and their SAE/API equivalents. NOTE: Overhaul/technical manuals are not required unless specified on the Invitation for Bids. 19. DATA SHEET: The attached data sheet should be completed and submitted in duplicate for informational purposes only. PART III ACCEPTANCE AND PAYMENT 1. ACCEPTANCE INSPECTION: Equipment reconditioned under this specification will be subject to acceptance inspection and performance testing upon receipt. Acceptance inspection and performance testing will not take more than five working days weather permitting. The vendor will be notified within this time frame of deficiencies found in the unit. 2. PAYMENT: Payment will be made within 30 days after the acceptance inspection has been completed and the TxDOT determines that the equipment meets specifications or the day on which a correct invoice for the goods or materials was received, whichever is later. 3. WORKING DAY: A working day is defined as a calendar day, not including Saturdays, Sundays, or regularly observed State and Federal holidays. PART IV WARRANTY 1. WARRANTY: The unit of equipment shall be warranted against all defects in material and workmanship for a period of not less than 12 months or 1,200 hours of use, whichever comes first, and shall cover 100 percent parts and labor for the unit. If manufacturer's standard warranty period exceeds 12 months or 1,200 hours, then the standard warranty period shall be in effect. The diesel engine shall be warranted against all defects in material and workmanship for a period of not less than 24 months or 2,400 hours of use, whichever comes first, and shall cover 100 percent parts and labor for the engine. The warranty shall begin on the date the unit is determined to meet specifications and is accepted into TxDOT's fleet. 4-5

5 DATA SHEET Bidders should insert the requested information and return two copies for informational purposes only. Failure to complete this information and to return the data sheets may result in rejection of the bid. Requisition No. Opening Date Loader: Make Model Operating Weight Wheelbase Diesel Engine Make Model Cycle Fuel Type SAE Net HP at Governed RPM, SAE Net Torque Lbs./Ft. Alternator Amps. Dry Type Air Cleaner Make Model Cab Heater BTU's Hourmeter Make Model Transmission Make Model Type No. of Speeds Forward Reverse Size of Tires Ply Rating Type Braking system meets SAE J1473 at time of manufacture Backup alarm meets SAE J994 at time of manufacture Machine Warranty Period is Months Engine Warranty Period is Months 1-2

6 Name and address of firm nearest the FOB point that will provide warranty service and repair parts: Firm Name Address Telephone Number Individual to Contact If servicing dealer furnishes parts for minor repairs by TxDOT personnel, will this affect the warranty?. If answer is "yes" please attach explanation. Name of Firm Bidder's Signature Bidder's Telephone No. Print or Type Bidder's Name NOTE: THIS PAGE SHOULD BE RETURNED FOR INFORMATIONAL PURPOSES ONLY. FAILURE TO COMPLETE THIS INFORMATION AND TO RETURN THE DATA SHEETS MAY RESULT IN REJECTION OF THE BID. 2-2