Draft - SOW MAR2024.pdf

U.S. DOT/Volpe Center V3352261

U.S. Army Switcher Locomotive

Statement of Work March 2024

Description This Statement of Work (SOW) specifies the manufacture and delivery of up to two 4-axle Switcher locomotives with current EPA Tier emissions certified diesel engine(s) and a complete range of technical data, materials, and equipment necessary to ensure long term compliance, operations, support, and maintenance for the locomotives. The locomotives may consist of a single or multiple engine design.

This specification is for the following items.

1. Contract Base Item: One 120-ton rear-cab configured (such as that the long hood is considered the front), switching style locomotive, including delivery, commissioning, and one year’s worth of spare parts. This locomotive shall offer no less than 1,200 horsepower and have non-center-alignment couplers installed after delivery during commissioning. The destination for this locomotive is Crane Army Ammunition Plant, Indiana.

2. Contract Option Item: One 140-ton cab-forward (short nose) configured road switcher locomotive with low hood, delivery, commissioning, and one year’s worth of spare parts. This locomotive shall be capable of providing no less than 1,800 horsepower. The destination for this locomotive is Fort Bliss, Texas.

Compliance Locomotive must satisfy the following:

a. Association of American Railroads (AAR) Manual of Standards and Recommended Practices Section-M, Locomotives and Locomotive Equipment

b. AAR Interchange Rules for delivery to destination by rail

c. The Official Railway Equipment Register

d. Code of Federal Regulations (CFR) Title 49, Part 229 Railroad Locomotive Safety Standards

e. American Society of Mechanical Engineers, Boiler and Pressure Code Section IX, Welding Qualifications

f. American Welding Society D15.1 - Railroad Welding Specification

g. American Iron and Steel Institute Standards

Order of precedence In the event of a conflict between the text of this SOW and the references cited herein, the text of this SOW takes precedence. Nothing in this SOW, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

General Configuration Specifications These specifications are for the base item and option item locomotives unless specified otherwise.

a. Model Type – Freshly manufactured, single or multi engine, four-axle switcher locomotive. A requalified frame is acceptable.

b. Emissions - In compliance with Environmental Protection Agency (EPA) Tier Locomotive Standards (CFR Part 92) and EPA Tier non-road Compression Engine Standards (CFR Part 89).

Must meet current TIER Emissions requirements at time of delivery.

c. For the Option Item locomotive:

• AAR Standard, alignment control type (self-aligning), type E or F shelf couplers, on both ends, top operated as outlined in rule 18.

• AAR S-580 Crashworthy

d. 390/391 series draft gears or similar, approved for road-switcher locomotives.

e. Operable/automatic sanders for wheel adhesion in direction of travel, controlled automatically by microprocessor and manual application.

f. Locomotive(s) shall not be equipped with a toilet.

g. Contractor shall provide maintenance item consumables (filters) and spare parts for the proper operation for one-year of operating service after locomotive delivery to destinations. This does not include fuel and lube oil.

h. Contractor shall provide locomotive operator and maintenance training at location of delivery.

Training requirements include hands-on operations with on-site personnel within thirty (30) days following delivery and acceptance of the locomotive(s).

i. Locomotive shall conform to AAR Plate-C clearance dimensions.

j. Crashworthiness design with anti-climbers per AAR Rules and Regulations.

k. Over speed set at 35 miles per hour (MPH) with signage indicating this located in the cab.

l. Locomotive shall be manufactured on new or requalified frame.

m. Underframe shall be new or qualified reconditioned, damage free and structurally intact.

Air and Brakes

a. CCB26 or equivalent AAR electronically controlled pneumatic brake system with self-test feature and fault tracing capability and compatible with the 26L air brake schedule

b. Automatic drain valves on bottom of drain on primary air system along with a manual drain.

c. Independent brake valve control pressure set for 72 PSI standard brake cylinder

d. Basic duplex air end connection

e. Automatic and independent brake vented to atmosphere below the cab floor

f. Immediate pneumatic knockdown to idle

g. All air piping shall be new

h. Main reservoir safety valve shall be set at 150 PSI

i. New composition brake shoes (if brake shoes are worn more than 50% during transport to destination a set of new brake shoes must be provided and installed)

j. Emergency brake valve located in cab

k. Six (6) seconds delay on penalty brake application (overspeed, etc.)

Cab

a. Air Conditioner to be of the type designed for locomotives (not RV type) with air condition condensate drain tubing extending to below the cab

b. Federal Railroad Administration (FRA) card holders (for Blue-card and Daily-card)

c. Window awnings (2), wind deflectors with full length mirrors (2), sun visors,

d. Pneumatic operated windshield wipers located at four corners and forward center window.

e. New fabricated steel cab and hood

f. AAR 105 standard Control Stand Operator’s console

g. AAR Clean Cab, cab door cushion pads, door closure bars, flexible hinge guards, etc. per AAR

h. Cab noise shall conform to CFR 49 section 229.121

i. High impact window glazing to comply with CFR 49 section 223

j. One operator seat and two sidewall mounted helper seats slide mounted

k. Non-skid flooring shall be applied on floor

l. insulation applied under floor

m. Cab lighting shall conform to 49 CFR 229.127

n. Cab mounted First Aid kit and Fire Extinguisher (see Other Provisions)

o. Doors shall be equipped with interior deadbolt locks. The front door shall be equipped with an exterior slide lock with four (4) matching keys per locomotive

p. Motorized auto-crank handbrake

Electrical/Electronics

a. Automatic ground relay system (fault history capable)

b. All circuits tested for continuity and load capacity

c. Locomotive shall be equipped with a working event recorder and non-resettable duty cycle recorder that meet current crashworthiness standards. Non-resettable duty cycle hour meter shall offer the following function, Notch Location (Idle and positions 1-8 and Total Hours per notch location).

d. One laptop containing software required to download history data, perform diagnostics and capable of downloading locomotive fault codes, including cables required to interface with locomotive is required.

e. Locomotive shall be equipped with a speed indicator which is accurate to within +/- 3 MPH for speeds of 10 to 30 MPH. Speed indicators must be clearly readable from the operator’s normal position under all lighting conditions

f. Safety Alerter compatible with speed indicator and event recorder

g. New batteries with central point watering/maintaining system compatible with the Flow-Rite Controls ™ portable watering cart.

h. New wiring and cabling insulated and approved per AAR

i. Locomotive shall have a console mounted programmable radio with handset and handset holder

(operating frequencies to be identified after contract award)

j. Roof mounted alerting strobe light (amber color) located near front center

k. Locomotive shall be equipped with operative crossing bell and horn in compliance with CFR 49

Part 229.129

l. Active ditch lights that automatically flash when crossings are approached in accordance with

CFR Title 49 section 229.125. The flashing shall be capable of manual activation or deactivation

m. New electrical cabinets with weather seals and ventilation

n. External electrical cabinets are to have a means for water drainage in the event the door seals/gaskets fail to resist water penetration

o. All doors and cover plates guarding high voltage equipment shall be marked “Danger High

Voltage” or “Danger”

p. Comply with AAR S-5502, Automatic Engine Start/Stop System

q. Two headlights provided at both ends of the locomotive

r. Illuminated number lights at both ends of the locomotive

Multiple Unit (MU) Operation

a. Locomotive shall be wired to AAR standard 27-wire train line, basic AAR pin arrangement, and be ready for Multi-Unit Operation with other locomotives similarly configured and equipped with MU operation. 27-pin receptacles shall be located on both ends of the locomotive. Dummy receptacles shall be placed on the opposite side of the working 27-pin receptacles

b. MU jumper cable shall be supplied (two per locomotive)

Wheels and Traction

a. D77 or equivalent traction motors (four) with new support bearing seal rings

b. Microprocessor controlled wheel slip protection and traction control

c. Individual traction motor isolation/cut-out

d. Gear case halves shall be fastened together without the use of “C” clamps

e. Gear Ratio 62:15

f. Two-axle truck arrangements

g. New, 40-inch (1016 mm) diameter, cast steel wheels

h. Wheel sets shall conform to 49 CFR 229.73

i. Cooling system for traction system shall be supported with documentation that includes all parts with corresponding part numbers

Main Engine(s)

a. The design and fabrication of the diesel engine(s) shall offer the structural integrity appropriate for locomotive switching operations and sized to achieve continuous locomotive power and the environmental constraints listed herein.

b. Main engine(s) utilized shall offer the following characteristics:

i. Overall power: no less than 1,200 horsepower for the rear-cab locomotive and no less than 1,800 horsepower for the forward-cab Option-item locomotive. This may be achieved by utilizing a single or multiple engine configuration.

ii. Engine must enable the locomotive to be certified as Ultra-low Emitting Locomotive (ULEL)

iii. Classified as heavy-duty industrial engine approved by the engine manufacturer for use in locomotives for road-switcher duty service.

c. Built-in engine protectors (voltage, frequency, current, temperatures, oil, and coolant) with auto shutdown and audible alarm feature.

Fuel Tanks

a. New fuel tanks, AAR S-5506 compliant or new double wall anti-rollover spill design

b. Snyder fuel fitting on filler pipes

c. Fuel level sight glasses, in addition to electronic gauges, with new gasket material shall be located on both sides of the fuel tank

Special Tools and Procedures

a. The Contractor shall identify Test, Measurement and Diagnostic Equipment that will ensure the ability of the locomotive to perform as originally designed. Maintenance concepts shall include optimum use of accurate on-board diagnostic capability to include Built-in Test (BIT)/Built-in Test Equipment (BITE) to the maximum extent possible. The Contractor shall maximize the use of embedded BIT/BITE dialogistic capability, fully document and support embedded systems and software; software shall not contain proprietary restrictions.

b. All special cabling and connectors for downloading diagnostic results including passwords for obtaining rights to access self-diagnostic software shall be presented during training.

c. Any tests associated with the mechanical or electrical aspects of the locomotive shall be clearly defined including all tools required to perform the tests.

d. Tools that are unique to this type of locomotive and are required to perform maintenance shall be delivered with the locomotive.

e. Basic items such as filters and tools required to perform regular maintenance shall be identified with part numbers and tracked in appropriate documentation.

f. The blue cab card will denote: “Event Recorder Equipped” and “Locomotive Handbrake Tested, Inspected and Lubricated at Annual Inspection” per requirements of 49CFR 232.105(c)”

g. Locomotive shall be delivered by railroad, fully manufactured as one complete unit.

Other Provisions

a. Contractor to invoice the Volpe Center after a successful final inspection and acceptance of all requirements at destinations.

b. Contractor shall mount one Manufacturer’s Builder data plate on the right front side sill of the locomotives with the following data:

1. Unit number

2. Model

3. Serial number

4. Build Date

5. Engine type

6. Horsepower

7. Gross Weight on rail

8. Manufacturer

9. Customer: “U.S. Army”

10. Contract number

c. Two 20-lb (9 kg) BC-type fire extinguishers shall be provided (one cab mounted and one engine room mounted)

d. One first-aid kit including items for treating minor injuries shall be mounted in the cab

e. One cab mounted flare box

f. Hand railings shall be provided on all exterior walkways. Throughways shall have chains with breakaway links installed

g. Locomotive fabrication shall be designed to direct effluents to a retention tank with a minimum capacity of 75-gallons

Training With locomotive delivery, the Contractor shall be responsible for initial set up for service and provide on-site operator training, hands-on maintenance, service and troubleshooting training, and a training package of materials. Two sets of special tools including software required to perform all maintenance functions will be provided during training, technical manuals and other applicable documents used to identify parts and service manuals required to perform maintenance shall be utilized during the training activities.

Training shall take place within 30-days following locomotive delivery and will be coordinated by the Government.

Painting and Stenciling Contractor shall follow AAR requirements for surfaces that are not to be painted. Ferrous metal surfaces to be painted shall be cleaned by sandblasting, commercial grade grit blasting, or mechanical or chemical means to remove all existing loose paint or other materials. Ferrous surfaces requiring finish painting shall be primed with rust inhibiting high solids, low volatile organic compound (VOC) urethane compatible primer. Dry film thickness shall be in accordance with the paint manufacturer's instructions for locomotive application. Paint specifications for locomotive shall conform to AAR Standard M-1001 Section C, Part II, Section 5.2.

Paint Classification: Polyurethane Substrate: Primed Steel Pre-treatment: Sandblasted Federal Color Standard (595B): White #17925

Black #17038 Yellow #13538 Red #11105

Paint Application: (Contractor shall provide a concept graphic prior to paint & stenciling applications)

a) Locomotive body: Red on cab forward unit. Yellow on rear-cab unit

b) Underframe/trucks: Black

c) Handrails: Yellow on cab forward unit. Black and white on rear-cab unit.

d) Steps: Black with reflective strip on front of each tread

e) Cab interior: Manufacturer’s beige, gray, or tan enamel

f) Stenciling on cab forward unit: Yellow stenciling: “USAX” on the cab, both sides with the locomotive number (to be determined) centered below the USAX marking, See Figure 1 for reference.

Yellow (United States Army) to be located on both sides, centered along the hood of the locomotive. No smaller than 9-inch lettering equally spaced. All other stenciling as required by

AAR.

g) Stenciling on rear-cab unit: Black stenciling: “USAX” on the cab, both sides with the locomotive number (to be determined) centered below the USAX marking, See Figure 1 for reference. Black

(United States Army) to be located on both sides, centered along the hood of the locomotive. No smaller than 9-inch lettering equally spaced. All other stenciling as required by AAR.

h) Chevron striping on front (angled 45-degree, downward toward the center) 6-inch (15 cm) yellow stripes equally spaced on forward cab unit. No stripes applied on rear-cab unit.

i) Stencil “F” located on the side sills near the front end.

j) Locomotive identification shall comply with 49 CFR Section 229.11.

k) Additional markings shall be in accordance with AAR Section L– Lettering and Marking of Cars, as applicable.

l) Only component supplier will paint telescoping portions of uncoupling lever.

m) The locomotive shall comply with Reflectorization Rules, 49 CFR Section 224.

n) Catwalks and external access areas such as the short nose to be coated with black non-skid finish.

Figure 1, Stenciling Representation on Forward Cab Model

Documentation All electronically formatted documentation shall be compatible with Adobe Acrobat Reader with the ability to be electronically reproduced for Government use.

a. The Contractor shall provide commercial off the shelf original equipment manuals for all major components and subassemblies including but not limited to engines, motors, compressors, HVAC, and generators. Contract compliance shall be subject to documentation review and approval of a Government representative.

b. The Contractor shall provide parts manuals, service manuals and operator’s manuals that meet the requirements described below as a minimum. Contract compliance shall be subject to documentation review and approval of a Government representative.

c. Technical data descriptions used to describe parts, assemblies and equipment shall consist of data such as specifications, standards, drawings, photographs, sketches, and descriptions, and the necessary assembly and general arrangement drawings, etc. required to indicate the physical characteristics, location, and function of the item.

Parts/Service Manual The locomotive parts/service manual shall be designed to provide quick access to information for the experienced and novice user. The parts/service manual will provide parts pages and component illustration pages and shall provide a description for all mechanical assemblies and all special tools required to perform repairs if failure occurs. Safety will be announced in appropriate areas. This description shall describe and illustrate the assembly and/or subassemblies contained in all main assemblies. The subassemblies will be illustrated in exploded view style and the breakout of parts will be cross-referenced by item number to provide identification by name and part number and quantity required. The part number is the manufacturer’s number for the component. This manual will also contain a description and tools required for the removal/replacement of each engine-generator.

Operator’s Procedure Manual The Contractor shall supply a stand-alone Operator’s Procedure Manual (OPM). The single or multi-engine locomotive OPM shall contain a step-by-step process for starting and shutting down the locomotive for all conditions (cold start, short downtime, limiting the number of engines to operate, etc.). This shall include all safety warnings and safety-related operations. This OPM shall also identify the limitations (time, amperages, temperatures, etc.) for when the locomotive is operating with one or two engines physically removed from service.

Documentation Package The complete documentation package consists of the following:

a. Locomotive dimensions and capacities

b. Component (part) identification

c. Maintenance Manual (including troubleshooting guide)

d. OPM (described above)

e. Parts/Service Manual (described above)

f. Lubrication orders

g. Electrical schematics and wiring diagrams

h. Diagrams of water, fuel, air, and lube systems.

i. All certifications, tests, repairs, and inspections

j. Manufacturer’s parts catalog (with pricing index if available)

With delivery of locomotive to destination, the Contractor shall provide complete documentation packages (as described above). Documentation package quantities and locations are described below:

a. One (1) CD-ROM copy to the Volpe Center, Cambridge, MA

b. One (1) CD-ROM copy to the U.S. Army (TBD)

The Contractor shall also provide to the Volpe Center and the U.S. Army, the authority to copy and distribute for their use, the documentation described herein.

With Delivery of Locomotive

a. Documentation Packages: One (1) CD-ROM copy and one (1) hard copy in binder form with locomotive delivery

b. Front door lock keys (four per locomotive)

c. Radio, air hoses, MU cables, etc. may be shipped separately from locomotive

Inspection of Locomotive All manufacturing, inspection and tests must be conducted and documented by an AAR certified shop which uses AAR approved practices and procedures and is recognized by the railroad industry. The Contractor’s facilities must be serviced by a railhead and be serviced by a recognized railroad. The facilities must also meet the Occupational Safety and Health Administration (OSHA) and EPA recognized standards. The locomotive shall be certified in writing that it meets the specifications and minimum requirements of the specifications contained herein. The Contractor is required to sign the Safety Certification form (Attachment A). The Government reserves the right to inspect the locomotive prior to any re-work/repair work proposed. Inspections may occur at the location of the repair or manufacture. Final acceptance will take place at Joint Base Charleston, South Carolina. The Government shall verify specification compliance at the point of final acceptance. The following check list shall apply:

Exterior

a. General overall appearance is clean and structurally correct as originally designed

b. Structural damage is nonexistent

c. No evidence of locomotive body sag or twist

d. Must be free from any corrosion or oxidation

e. Must be properly stenciled according to AAR interchange rules

f. Hood, doors and end arrangements conform to standards and operate properly

Underframe

a. The underframe shall be damage-free and structurally intact and have legible manufacturer’s builder plates Couplers

a. Check coupler castings and coupler pockets for repairs or cracks

b. Check for proper height of coupler [34½ inches (87.6 cm) from top of rail to center]

c. Check and measure coupler knuckle for operation and condition

d. Check for self-aligning couplers

Brakes

a. Check air brake cylinders and valves

b. Check reservoirs

c. Check angle cocks, both A and B end

d. Check all brake rigging

e. Check hand brake for operation and correct application

f. Check all safety hangers

g. Check for correct AAR/DOT pneumatic piston travel

h. Air brakes shall be tested and adjusted until satisfactory performance is obtained to comply with current AAR interchange rules, AAR Field Manual, and 49 CFR 229 Safety Appliances

a. Check for proper clearances and applications

b. Check to ensure handholds and sill steps installed are secured properly

c. Check Strobe light visibility

d. Identify crashworthiness components

Trucks

a. Gear Ratios

b. Wheel size

c. Springs

d. Wheels and tire defects per 49 CFR 229.75

e. Trucks per 49 CFR 229.67

Cabs, floors and passageways

a. Per 49 CFR 229.119

Miscellaneous

a. MU equipment

b. Speed recorder

c. Bell and horn

d. Sanders

e. Safety devices and markings including reflective tape

f. Cooling system

g. Protective devices

h. Low voltage circuits and equipment

i. Water tightness (including window seals)

j. Communications equipment

Areas to be inspected for compliance with AAR Interchange and 49 CFR include

a. Start and check for leaks

b. Shutdown and check temperatures

c. Operate locomotive for two hours performing switching, hauling freight, setting out cars, picking up cars.

Contractor Ability

a. Contractor shall notify the Volpe Center ten days prior to any testing.

b. Locomotive for Crane, IN must be delivered and commissioned by September 30, 2025.

c. All manufacturing, inspection and tests shall be conducted and documented by a shop which has AAR M-

1003 certification, uses AAR approved practices and procedures and is recognized by the railroad industry. If the shop does not have AAR M-1003 certification, an alternate quality assurance certification shall be deemed acceptable if the Contractor can prove equivalency and provide cross-reference to the AAR M-1003 requirements.

Spare Parts The Contractor shall submit a recommended spare parts list. Spare parts are those items recommended by the manufacturer to be kept on hand for quick and immediate maintenance access. This list shall identify the parts required to support the locomotive for one year of service. A one-year supply of spare parts as identified in the spare parts list shall be delivered with the locomotive and shall be inspected for completeness before acceptance.

Warranty The standard commercial warranty shall apply.

Sustainability To the maximum extent possible and consistent with FAR Part 23 and during the performance of the work under this SOW, the Government requires the Contractor to provide or use products that are energy efficient (ENERGY STAR® or Federal Energy Management Agency Program-designated), water-efficient, biobased, environmentally preferable (e.g., EPEAT-registered or non-toxic or less toxic alternatives), non-ozone depleting, or made with recovered materials. Unless otherwise identified in this SOW, each recovered materials or biobased product provided and delivered must meet, but may exceed, the minimum recovered materials or biobased content of an Environmental Protection Agency (EPA)-designated or US Department of Agriculture-designated product. These sustainable acquisition requirements apply only to products that are required to be (1) delivered to the Government during contract performance; (2) acquired by the Contractor for use in performing services (including construction) at a Federally controlled facility; (3) furnished by the Contractor for use by the Government; or (4) specified in the design of a building or work or incorporated during its construction, renovation, or maintenance.

End – Switcher Locomotive Statement of Work