Attachment B-Technical Specificaion Wheelsets & Traction Motor Ovehaul Repair & Rehabilitaion Services-final.pdf

IFB No.: 027-004 IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

ATTACHMENT B

Wheelset and Traction Motor

Overhaul, Repair and Rehabilitation

Specification

IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

ABBREVIATIONS AND ACRONYMS

Abbreviation Definition

AAR Association of American Railroads

CFR Code of Federal Regulations

GG Type GG journal bearing (locomotive application)

F Type F journal bearing (passenger railcar application)

FRA Federal Railroad Administration

HI-POT High Potential (dielectric) electrical test

IR Insulation Resistance

MI Maintenance Instruction

MPI Magnetic Particle Inspection

NDT Non-Destructive Testing

OEM Original Equipment Manufacturer

TS Technical Specification

TIR Total Indicator Runout

UT Ultrasonic Testing

VRE Virginia Railway Express

WACT Wheel/Axle/Traction Motor Assembly

Acronyms and abbreviations used but not defined herein shall be interpreted in accordance with applicable AAR, OEM, or industry-standard usage.

IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

1. Purpose and Intent

This Technical Specification defines the requirements for inspection, repair, overhaul, rehabilitation, testing, documentation, and return to service of wheelsets, axles, bearings, wheels, and traction motor assemblies owned by Virginia Railway Express (VRE). This specification is for maintenance services only and excludes design, manufacturing, modernization, system integration, or certification activities.

2. Applicability and Equipment

This specification applies to Gallery IV passenger railcars and MP36PH-3C locomotives, including associated wheelsets, axles, bearings, wheels, wheel/axle/traction motor assemblies (WACT), and EMD D77 traction motors.

3. Governing Standards

All work shall comply with applicable AAR standards, the AAR Wheel and Axle Manual, AAR Roller Bearing Manual, AAR Specifications M-101 and M-107, 49 CFR Part 238, American Public Transportation Association (APTA) PR-M-RP 008-98- Recommended

Practice for Passenger Care Axle Design, APTA PR-M-S-012-99– Standard for the

Manufacture of Wrought Steel Wheels for Passenger Cars and Locomotives and applicable OEM requirements.

4. General Requirements

All components shall be inspected upon receipt. Major repairs or replacements require written VRE approval prior to execution of work by the Contractor. Components deemed unserviceable shall be documented and dispositioned only with VRE approval.

The Contractor shall ensure that required materials meeting applicable AAR, OEM, and

VRE requirements, including wide-flange wheels and compatible axles and bearings for both passenger railcar and locomotive applications, are available to support overhaul, repair, rehabilitation, and return-to-service activities without causing delays to scheduled work.

VRE reserves the right, but is not obligated, to furnish wheels, axles, or other materials from VRE-owned inventory when available. Use of VRE-furnished materials shall not relieve the Contractor of overall responsibility for meeting schedule and performance requirements.

Material availability, supplier lead times, or inventory constraints shall not be grounds for schedule relief, price adjustment, or change orders unless expressly authorized in writing by VRE.

IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

5. Wheelset Services

Wheelsets shall be inspected to determine whether re-profiling, repair, rehabilitation, or replacement is required and shall meet applicable wide-flange configurations.

6. Defined Work Scopes (Basis of Pricing)

The following work scopes define the minimum work included for each service and establish the basis of bid pricing. These scopes do not limit additional work required to return components to serviceable condition.

6.1. Passenger Railcar Wheelset Work Scopes

6.1.1. Replace Passenger Railcar Axle – Inspect wheelset; rebuild F-style journal bearings; remove wheels for reuse; provide and qualify new axle; bore and mount wheels; re-profile wheels; reinstall bearings.

6.1.2. Re-Profile Passenger Railcar Wheelset – Inspect wheelset; rebuild F-style journal bearings; re-profile wheels; reinstall bearings.

6.1.3. Replace Passenger Railcar Wheels – Inspect wheelset; rebuild journal bearings;

remove and scrap wheels; qualify axle; provide and mount new wheels; reinstall bearings.

6.1.4. Replacement Passenger Railcar Wheelset – Provide new axle, wheels, and journal bearings; bore, mount, and assemble complete wheelset.

6.2. Locomotive Wheelset / WACT Work Scopes

6.2.1. Re-Profile Locomotive Wheelset – Separate WACT; rebuild GG bearings; qualify axle; re-profile wheels; install new support bearing; reassemble and test.

6.2.2. Replace Locomotive Wheels – Separate WACT; rebuild GG bearings; replace wheels; install new support bearing; reassemble and test.

6.2.3.Replace Locomotive Wheelset - Provide new axle, wheels, and journal bearings;

bore, mount, and assemble complete wheelset.

6.2.4.Replace Locomotive Axle – Separate WACT; reuse wheels and bull gear; provide new axle; reassemble WACT; test for serviceability.

IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

6.3. Traction Motor Services

6.3.1. Basic Overhaul of Traction Motor

Applies to EMD D77 traction motors only and shall be performed strictly in accordance with applicable OEM Maintenance Instructions (MI), including EMD MI-3950 or its current equivalent. Includes complete disassembly, inspection, overhaul, reassembly, and testing.

Where inspection of a component is identified as a mandatory inclusion, the Contractor shall include in the Basic Overhaul price any incidental corrective actions required to return the component to compliance with OEM Maintenance Instruction acceptance limits.

Electrical tests shall be performed using OEM-specified procedures, voltages, durations, and acceptance criteria. Any re-testing required to achieve acceptable results shall be included in the Basic Overhaul unit price.

For bidding purposes, the Contractor shall assume that all inspection, cleaning, incidental corrective actions, and verifications necessary to meet OEM Maintenance Instruction acceptance criteria are included in the Traction Motor Basic Overhaul unit price, except where explicitly excluded.

For bidding purposes, the Traction Motor Basic Overhaul shall be priced assuming that field coils are serviceable and do not require replacement or repair.

For bidding purposes, the Traction Motor Basic Overhaul shall be priced assuming the armature is serviceable and does not require rewind.

6.3.1.1. Mandatory Inclusions

All items listed below are mandatory and shall be included in the price of a Traction

Motor Basic Overhaul.

• Complete disassembly to component level per OEM MI

• Cleaning and baking/drying of armature and frame as required by MI

• Mandatory replacement of bearings, seals, gaskets, and one-time-use hardware

• Electrical testing: IR, Hi-Pot, Surge, Winding Resistance, No-load Run

• Mechanical inspection of commutator, shaft, journals, and gear interfaces

• Reassembly strictly per OEM MI

• Documentation: MI compliance certification, test reports, pinion traceability

IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

Pinion The traction motor pinion shall be replaced with a new pinion during every

Basic Overhaul. Reuse of an existing pinion is not permitted.

Traceability Requirement: New pinions shall be fully traceable by manufacturer, part number, serial or unique identifier, heat number if applicable, material certification, manufacturing date, and OEM/AAR compliance. Records shall be included in the final acceptance package by the Contractor.

Traction Motor Leads:

Replacement of traction motor leads determined to be unserviceable in accordance with applicable OEM Maintenance Instructions shall be included in the Basic

Overhaul unit price and shall not be separately billable.

Frame repairs:

Miscellaneous traction motor frame repairs necessary to restore the frame to serviceable condition in accordance with applicable OEM Maintenance Instructions shall be included in the Basic Overhaul.

Included miscellaneous frame repairs may consist of minor crack repair, thread repair, boss repair, gasket surface cleanup, and correction of localized defects that do not alter critical dimensions or structural interfaces.

6.3.1.2. Exclusions

The following are excluded unless authorized in writing by VRE: armature rewind, field coil replacement, shaft replacement.

• Major frame repairs

• Axle bore welding, metal build-up, or sleeve installation

• Axle bore machining, line boring, or dimensional restoration

• Bearing seat welding or machining

• Structural frame modification or redesign

• If inspection or testing performed during a Traction Motor Basic Overhaul determines that an armature does not meet OEM Maintenance Instruction acceptance criteria and requires rewind, the Contractor shall immediately notify VRE in writing. No armature rewind work shall be performed without prior written authorization from VRE.

• If inspection or testing performed during a Traction Motor Basic Overhaul determines that field coils do not meet OEM Maintenance Instruction acceptance criteria and require replacement or repair, the Contractor shall immediately notify VRE in writing. No field coil replacement or repair shall be performed without prior written authorization from VRE.

IFB Title: Wheelset and Traction Motor Overhaul, Repair, and Rehabilitation Services

Virginia Railway Express

The Traction Motor Basic Overhaul shall be priced assuming worst-case conditions within the defined scope of work and shall not be based on assumptions of minimal wear or exceptional incoming conditions.