Attachment_F_-_Geometry_Car_Maintenance_Information.pdf

Attachment F

ATTACHMENT F

Geometry Car Maintenance Information

GEOMETRY CAR MAINTENANCE INFORMATION

PERIODIC AND PREVENTIVE MAINTENANCE

INTRODUCTION

Due to the high mobilization cost and sensitive nature of the ATIP program, it is imperative to minimize troubleshooting and repairs required during survey operations. This is achieved through a comprehensive periodic and preventive maintenance program. Original Equipment Manufacturer (OEM) maintenance manuals and operational experience were used to compile the following list of Maintenance Requirements. The frequency of maintenance actions was stated in several different units of measure; distances traveled, calendared periods (weekly and monthly), operating hours, etc. Based on the anticipated usage and operating schedule, OEM prescribed maintenance actions have been placed on the attached checklists to be completed at different intervals (daily, weekly, monthly, quarterly, annually, etc.) to be completed without exceeding the recommended maintenance interval.

The attached checklists are considered living documents and are to be updated as onboard equipment changes, additional inspection requirements are established, or conditions otherwise warrant.

In addition to routine maintenance activities, repair actions must occasionally be performed to onboard equipment. Typically repairs are completed by the contractor, although repairs may involve support from sub-contractors or other outside vendors. Additional funding may be required to perform unforeseen high cost repairs.

RESPONSE TIME

In the event of a system or component failure, the contractor, in conjunction with the FRA, will determine whether the failure is mission-critical or not. Critical failures prevent the car from meeting its survey mission.

Mission Critical In the event of a mission critical failure, the contractor will direct the onboard crew to make immediate, appropriate repairs. If it becomes apparent that repairs cannot be made by the contractor within 4-hours, the contractor will notify the COTR at FRA HQ within the 4-hour period by phone or any other means available. The contractor will then also contact appropriate repair facilities to expedite the repair of the failure. The repair of failures will be documented as per Equipment Monitoring Requirements (discussed later) and will remain as Open Maintenance Items until the repair is properly documented.

An example of a Mission Critical failure is a failure of the gage measuring system. If track gage were not being measured properly, survey operation would cease until repaired. Repairs would commence immediately.

Non-Mission Critical In the event of a non-mission critical failure, the contractor will document the failure in a failure log and direct the appropriate personnel to make repairs at the appropriate time. The appropriate time for repair may be during a railroad delay, at the termination of the day’s survey, or during the next maintenance period. The repair of failures will be documented as per Equipment Monitoring Requirements (later) and will remain as Open Maintenance Items until the repair is properly documented. The status of all Open Maintenance Items will be maintained in the failure log. An example of a Non-Mission Critical failure is the malfunction of a single diesel generator, the failure of which would not require survey operations to cease immediately, as there is a redundant diesel generator available and capable of supplying adequate power to all other systems.

Equipment Repair The contractor will maintain a record of railroad repair facilities used throughout the US along with the capabilities of each. When required, the contractor will arrange to have repairs made with the appropriate facility. Additionally, the contractor shall identify non-railroad vendor locations for repair of major component systems. (Diesel, generator, transmissions, etc.)

MAINTENANCE OPTIONS REQUIRED

New Equipment During the term of this contract, the FRA may add at its option, equipment to this contract. As long as maintenance charges for the added equipment is (1) for the same type and model number, the charges specified in the contract or (2) for items not specified in the contract, a mutually agreed charge no greater than the OEM's GSA schedule charge or commercial charge, if no schedule is available.

Features During the term of this contract, the FRA may add new features to its installed equipment base. When features are added to a device, the contractor must accept maintenance responsibility for these features under the terms, conditions, and prices stated in the contract. If a similar feature is not in the contract, the maintenance charge will be mutually agreed upon. If a cost cannot be negotiated, the contractor shall accept the OEM's GSA contract maintenance price for the feature. Maintenance charges shall not exceed the OEM's GSA schedule maintenance price or commercial charge, if no schedule is available.

Preventive Maintenance Preventive maintenance shall be scheduled to be performed so as not to interfere with the FRA's operations. The frequency, duration, and quality of preventive maintenance shall be equal to that provided by the OEM for similar equipment under their standard commercial maintenance contracts.

EQUIPMENT MONITORING REQUIREMENTS

Issue Tracking The contractor shall establish a means to document and track issues identified with the geometry vehicles and their onboard systems. The issue tracking system should form the basis of the maintenance reporting system. The issue tracking system should enable users to enter, update, close, and query issues for a particular car.

Reporting Upon completion of a scheduled maintenance period or repair activity, the contractor shall submit written status reports that include, as a minimum, the following:

• A summary of the maintenance and repair actions conducted during the maintenance period,

• Details of any failures and/or repairs performed during the three-week operational surveys and the weekly maintenance period,

• Any engineering changes announced by OEM and the contractor's plans for installation,

• Outstanding issues and the contractor’s plan to address them

• Any other items relevant to maintaining the geometry car equipment.

DOTX-216 DAILY MAINTENANCE CHECKLIST

Rev: 9 Effective Date: 6/1/12

Site: Date: RR: Avg Temp:

Signature after completion of Class I Brake Test: Time:

Task Maintenance Objective and 49 CFR Reference Complete Braking

D1 Verify wheel slide detection system is powered on by observing power LED through sight hole in cover D2 Verify shoes/pads are not loose, missing key, or improperly aligned with braking surface. 238.313(g)(2,5) D3 Verify shoes are not worn to a thickness of ⅜” or less. 238.313(g)(9) D4 Verify pads are not worn to a thickness of ¼” or less. 238.313(g)(9) D5 Verify brake disks do not have cracks over 3” in length or within ½” from edge of disk. 238.313(g)(13)

D6 Verify Graduate/Direct release cap is properly positioned for service. (DIR for normal operation, GRA for Amtrak) 238.313(g)(10)

D7 Verify brake indicators are operational. 238.313(g)(14) D8 Verify proper operation of hand brake. 238.313(g)(11) D9 Check for air leaks. 238.313(g)(7)

D10 Verify end of car brake hoses and main line hoses are secure D11 Drain air reservoirs D12 Ensure train crew is operating at 110 psi on the brake pipe D13 Observe train crew perform initial terminal Class 1 air brake test 232.205

Car Body D14 Ensure chlorinator has 1 tablet. Verify lid and gasket are secure. Lubricate Gasket. 229.139(b)(3) D15 Check operation of toilet for correct timing and presence of water. 229.137 D16 Verify presence of water at sinks and toilet, fill water tank if low level suspected.

D17 Verify coupler head, shank, and components free of cracks, breaks, and bends. 238.303(e)(3) D18 Verify cut levers are not bent or broken and are free from obstruction.

D19 Verify cut levers are secured in down (locked) position with coupler locked.

D20 Verify telltale recess and/or telltale hole are fully visible with coupler fully locked. 238.303(e)(3)

D21 Verify coupler knuckle and coupler shank pin retaining key are not missing, cracked, broken, or worn more than 25%.238.303(e)(3,4)

D22 Verify lock lift assembly has proper rod eye clearance with coupler locked and centered.

D23 Verify coupler carrier is not broken or cracked. 238.303(e)(3) D24 Verify coupler yoke is not broken or cracked. 238.303(e)(3)

D25 Verify diaphragm and buffer plates are in place, properly aligned, and do not have unsafe high/low condition.

238.303(e)(13-14)

D26 Verify a device is present under each drawbar pin to prevent the pin from falling out in case of breakage 238.303(e)(4) D27 Verify all parts or appliances, except the wheels, are more than 2½” above the top of the rail. 238.303(e)(9)

D28 Verify floors are free from slipping, tripping, or fire hazards, and floors are properly treated to provide secure footing.

238.305(c)(2)

D29 Verify all trap doors safely operate and securely latch in place in both the up and down position. 238.305(c)(8) D30 Verify all vestibule steps are illuminated. 238.305(c)(9) D31 Verify all end doors and side doors operate safely and as intended. 238.305(c)(10) D32 Verify security of generator access, storage box, battery access and all other access doors on outside of vehicle

Electrical Power and Controls D33 Check oil level and antifreeze level of generator engine D34 Inspect generator set; wiring, fluid lines, brackets, belt, fan, filter screen and overall condition for any defects D35 Check generator for unusual noises after engine is started D36 Verify generator engine monitoring system from the panel next to the electrical locker D37 Check fuel level and top off as necessary D38 Verify operation of ditchlights, marker lights, and interior emergency lights. 238.307.(c)(5) D39 Verify train battery voltage on solar charging unit. Should be > 64 volts.

D40 Verify operation of battery charger next to electrical locker D41 Verify windshield wiper operation on F-End of the car D42 Verify (if applicable) that 480v HEP is not short looped.

D43 Verify 480v cables and cable connections are located and guarded in a manner that provides sufficient vertical clearance, and do not hang with one end free. 238.303(e)(11) D44 Verify each battery container is vented and each battery is kept from gassing excessively.238.303(e)(2) D45 Verify 480v cable insulation is not broken, or chaffed, and no strands of wire are broken or protruding. 238.303(e)(11) D46 Verify no plug, receptacle, or terminal is broken. 238.303(e)(11) D47 All carbody to truck, and truck to bearing adaptor grounding straps are in place. 238.303(e)(10)

Geometry System D48 Perform beam and hardware inspection of primary geometry beam per ATIP-MN-W001 D49 Check geometry wiring for chafing or breaks and verify instrumentation is mounted securely D50 Check condition of both tachometers on the ends of axle 1 D51 Clean laser and camera windows on each 3DM sensor head per ATIP-MN-W006

Safety Appliances D52 Verify no safety appliance is broken, bent, cracked, or missing.

D53 Verify handhold minimum clearance is greater than 2”.

D54 Verify exit identifications are not missing. Operating handles must not be broken or improperly installed.

238.305©(3); 239.107(a)

D55 Verify all doors and cover plates guarding high voltage equipment are marked “Danger High Voltage” or “Danger” and normal voltage carried by parts. 238.303(e)(12); 238.305©(6)

D56 Verify all potentially dangerous parts, pipes or electrical components are installed in non-hazardous locations or equipped with guards to prevent personal injury. 238.305©(1)

D57 Verify the words “BRAKE for Emergency Use Only” are legibly marked near each brake pipe valve. 238.305©(5)

D58 Verify all emergency equipment is in place and fire extinguishers are in date and have not been discharged.

238.305©(4)

D59 Verify all safety signage is in place and legible. 238.305©(7) Suspension

D60 Verify bearing end cap, end cap screws, and locking plate are not cracked, loose or missing. 238.303(e)(16)

D61 Verify roller bearing grease seals are not loose, cracked, misaligned, or damaged; and do not show excessive fresh grease leakage. 238.303(e)(16)

D62 Verify bearing adapters are in proper position for service.

D63 Verify bearings do not show signs of overheating. 238.303(e)(16) D64 Verify levers, rods, brake beams, and hangers are properly secured and are not worn more than 30%.238.303(e)(6) D65 Verify pedestal liners, tie straps, tie bars, and retainers are not loose, broken, or missing. 238.303(e)(6) D66 Verify shock absorbers are not broken or leaking oil and are properly secured. 238.303(e)(5) D67 Verify bolster/radius rod is not loose or missing. 238.303(e)(6) D68 Verify side bearing assemblies have proper clearance. 238.303(e)(7) D69 Verify coil springs are not broken or fully compressed. 238.303(e)(5) D70 Verify truck safety hangers are not missing, cracked, or broken. 238.303(e)(5) D71 Verify hangers, bolts, gibs, or pins are not cracked or broken. 238.303(e)(5) D72 Verify truck frame is not broken or cracked in a stress area. 238.303(e)(6) D73 Verify wheel flange thickness is not 1” or less.[CFR ⅞”] 238.303(e)(8) D74 Verify any wheel flat spots, shelling, and spalling do not exceed 1.5” in length. [CFR 2½”]238.303(e)(8) D75 Verify wheel flange height is not 1 ⅜” or greater. [CFR 1½”] 238.303(e)(8) D76 Verify wheel rim thickness is not 1 1/16” or less. [CFR 1”] 238.303(e)(8) D77 Verify wheel does not have any cracks or breaks. 238.303(e)(8) D78 Verify chips or gouges in wheel flange do not exceed 1.5” in length and .5” in width. 238.303(e)(8) D79 Verify wheel set does not have a scrape, dent, gouge, or grooved tread 1/8” or greater depth.

D80 Verify axle is not cracked, broken, or bent. 238.303(e)(8)

D81 Verify wheels do not show evidence of overheating or discoloration on front and back of plate that extends 4” into plate.

D82 Verify lengthwise wheel tread seams or grooves are not within 3 ¾” of the flange or ⅛” or more in depth.

D83 Verify wheels are not loose or have any welds. 238.303(e)(8) D84 Verify wheel tread worn hollow does not exceed 5/32” [CFR 5/16”] 238.303(e)(8)

DOTX-216 Weekly Maintenance Checklist

Task Maintenance Objective Complete Complete other inspections

W1 Perform Daily Inspections and complete inspection checklist Carbody

W2 Check oil level of microphor oiler, top off as necessary.

Electrical Power and Controls

W3 Drain water from Racor fuel/water separator bowl

W4 Determine hours since last service for generator. Perform periodic maintenance as appropriate GE Current Hours: Hours at last service: Hours Since Last Service:

DOTX-216 Periodic Generator Maintenance at Oil Change Intervals of 250 hrs

Generator: #1 Engine Hours:

Task Maintenance Objective Complete

GE1-1 Clean Generator cooling air intake screens GE1-2 Change Engine Oil GE1-3 Change Oil Filter GE1-4 Change Air Filter GE1-5 Change Fuel Filter GE1-6 Wipe down generator, engine and frame

DOTX-216 Monthly Maintenance Checklist

Task Maintenance Objective Complete Complete other inspections

M1 Perform Daily and Weekly Inspections and complete inspection checklists Car Body

M2 Add one package of MicroCulture to the Microphor waste tank via the toilet M3 Flush chlorinator and downstream plumbing with water. Ensure proper drainage.

M4 Replace all Air Conditioner Air Filters M5 Inspect all passenger seating and seat attachments for anything loose or broken M6 Inspect all luggage racks for anything loose or broken M7 Inspect solar panels and mounting hardware. Clean panels as necessary. DO NOT PERFORM UNDER CATENARY M8 Drain condensate from compressor air tank M9 Clean / Replace Compressor Air Filter

Electrical Power and Controls M10 Inspect generator battery for overall condition of batteries and treat corrosion where necessary M11 Inspect train-line batteries for electrolyte level and overall condition. Treat corrosion as necessary M12 Perform Functional Test of Alarm System and Verify Data Collection M13 Inspect 480V, COMM, and MU cables and receptacles. Ensure receptacle covers self close.

Geometry System M14 Record current Software Build Numbers and Versions M15 Check and record all geometry system gains

Safety Appliances M16 Inspect flags, flag stands, derails, locks, and chocks. Apply high visibility paint if necessary.

M17 Check operation of security system

M18 Ensure latest version of maintenance checklists and forms are stored on General Purpose and restock checklist binder for crew use

M19 Record Wheel Profiles with MiniProf measurement system M20 Measure Wheels and Complete ATIP-MN-FORMS-011 – AAR Steel Wheel Gage Measurement Form M21 Check fluid level in shock absorbers M22 Grease fittings on shock absorbers

DOTX-216 Quarterly Maintenance Checklist

Task Maintenance Objective Complete Complete other inspections

Q1 Perform all Daily through Monthly inspections and complete checklists Car Body

Q2 Inspect door heaters, weather stripping, tracks, operation. Lubricate as needed Q3 Check HVAC system Freon levels Q4 Each coupler has not more than 5 1/8 inches between the knuckle nose and guard arm Q5 Each coupler does not have more than ½ inch of free slack not absorbed by friction devices or draft gears Q6 Verify the draft gear of each coupler is not broken

Electrical Power and Controls Q7 Perform Uninterrupted Power System (UPS) automated battery test Q8 Emergency lighting systems operational (CFR 238.307 © (5))

Q9 All hand operated electrical switches with potential for carrying more than 150 volts that may be operated while under load are covered and are operative from the outside of the cover;(CFR 238.307 © (6) (i))

Q10 Verify Electrical Switches marked to indicate open or closed position (CFR 238.307 © (6) (ii)) Q11 Check all (4) slip/slide system speed sensor mounts, wiring, and air gaps. Adjust to .032 inches as necessary.

Q12 Perform self test on E5 decelostat system Q13 Install new Racor fuel filter for Generator Engine

Geometry System Q14 Perform Geometry System calibration Q15 Perform beam and hardware inspection per ATIP-MN-W001

Safety Appliances

Q16 Verify all mechanical systems and components of the equipment are free from any discrepancies that may endanger the safety of the crew, passengers, or equipment

Q17 Clean all smoke detectors

Q18 Verify all trucks are equipped with a device or securing arrangement to prevent the truck and car body from separating in case of derailment

Q19 Verify all center castings on trucks are not cracked or broken, to the extent possible without jacking the car and rolling out the trucks

DOTX-216 Annual Maintenance Checklist

Task Maintenance Objective and 49 CFR Reference Complete Items to complete before car arrives Schedule Stadco Technician to come out to car to check and adjust overhead on Generator Engine Arrange Amtrak PC-1 Inspection Review date of last Amtrak PC-2 inspection. Arrange if necessary.

Complete other inspections

A1 Perform all Daily through Quarterly inspections and complete those checklists Braking System

A2 Perform annual brake maintenance per ATIP-MN-W007 A3 Inspect all brake caliper units and brake discs for any cracks, breaks, or other discontinuities A4 Inspect forward trucks brake rigging, lines, hoses and clamps for tightness and security A5 Inspect rear trucks brake rigging, lines, hoses, and clamps for tightness and security A6 Inspect end of car brake and main line hoses. Replace if damaged or more than 7 years old A7 Clean, inspect, lubricate, parking brake parts and components. Stencil parking brake with inspection date.

A8 Update Air Brake Maintenance Record ATIP_MN_FORMS_014 to reflect brake system changes

Car Body A9 Pressure wash roof of car and roof mounted equipment, outside body, and underside of car 10 Inspect condition of Microphor toilet hopper and flapper seals

A11 Inspect Microphor biological waste treatment tank, lines to and from the tank, and system chlorinator A12 Have Microphor biological waste treatment tank pumped and flushed out A13 Inspect each HVAC unit under the vehicle for noticeable flaws, wear, or damage A14 Clean and inspect the evaporator and condenser coils on each HVAC

Electrical Power and Controls A15 Inspect all generator engine wiring, connections, and terminations A16 Inspect generator engine fuel pump, fuel system lines and fuel hoses for leaks or abrasions A17 Inspect generator engines water pumps and radiator hoses A18 Inspect generator engine radiator for clogging at the radiator fins. Remove and have cleaned if necessary A19 Inspect generator engine accessory belts and associated equipment A20 Have generator engine serviced by Stadco Service Tech to inspect and adjust engine overhead and injectors A21 Inspect generator body and wiring for loose connections and overall tightness A22 Install new generator engine battery.

Geometry System A23 Remove all geometry system sensors and test equipment used for system calibration and ship in for calibration A24 Clean all geometry system computer air filters

A25 Upon receiving geometry system sensors and test equipment back from calibration verify each component has the correct calibration certificate and file per ATIP quality SOP

A26 Inspect geometry beam and mounting components per ATIP-MN-W001 A27 Replace exterior lenses in each 3DM sensor head A28 Perform reproducibility evaluation per ATIP-MN-08

Safety Appliances A29 Have annual inspection done on all fire extinguishers A30 Inspect and update first aid kit A31 Inventory and update vehicle flagging kit A32 Update inventory of blue lights A33 Update inventory of safety vests, hard hats, safety glasses, and ear plugs.

A34 Have PC-1 Inspection conducted

Suspension A35 Perform inspection of truck bogies A36 Remove link connection for each rotary damper and test resistance in each direction of movement A37 Have wheel gauges calibrated. File calibration certificates on the server.

DOTX-216 2 -Year Maintenance Checklist

Task Maintenance Objective Complete Electrical Power and Controls

2-1 Change Coolant in Generator Engine

DOTX-216 4 -Year Maintenance Checklist

Task System Maintenance Objective Complete 4-1 Braking Perform COT&S per ATIP-MN-W007 238.309(d)(2) 4-2 Suspension Roll out truck and inspect center casting for cracks and breaks 238.307(c)(9)

DOTX-217 DAILY MAINTENANCE CHECKLIST

Rev: 13 Effective: 5/14/12

Site: Date: RR: Odometer: Avg Temp:

Signature after completion of Class I Brake Test: Time:

Task Maintenance Objective and 49 CFR Reference Complete Propulsion

D1 Verify battery voltage at control panel in B6 closet is 24VDC for both drive engine battery sets D2 Verify fuel level, top off as necessary D3 Verify operation of sanding system 229.131 D4 Verify sander boxes are filled with sand, top off as necessary and verify covers and components are secure D5 Verify safety hangers on trucks, propeller shafts, and journal boxes are in place 229.65(a); 229.67(b); 229.99 D6 Check #1 Drive Engine oil level, alternator belts, external wiring, fluid lines and overall condition for any defects D7 Check #2 Drive Engine oil level, alternator belts, external wiring, fluid lines, and overall condition for any defects D8 Check coolant level of each drive engine at reservoirs on the roof of the car. Should be in the middle of sight glass D9 Check transmission fluid level for both transmissions

D10 Check axle gear box oil levels in all four units D11 Check transmission gear box declutch mechanism for proper position D12 Check oil level of front and rear hydraulic tank reservoirs D13 Check drive engines for unusual noises after engines are started D14 Monitor all driving desk indicated conditions while in operation D15 Verify Drive Engine monitoring systems function properly 229.101a

Braking D16 Verify slip-slide fault indicator in B6 closet reads “9999” after computer initializes and self-checks 229.115 D17 Drain all water separators, air reservoirs, centrifugal filters, and drip cans 229.131 D18 Verify correct position of all valves for operating mode (self-propelled or towed)

D19 Verify Graduate/Direct release cap is properly positioned for service. (DIR for freight towed operation, GRA for self-propelled or Amtrak) 238.313(g)(10)

D20 After pneumatic system is charged, verify system tightness and that there are no air leaks D21 Check oil level of all air oilers (main, brake, microphor) D22 Verify end of car brake hoses and main line hoses are secure D23 Perform initial terminal Class 1 air brake test 232.205 See ATIP-OP-003-W001 D24 Perform Class III brake test if operating end are changed 232.211 See ATIP-OP-003-W002 D25 Perform running brake test as soon as possible after each Class I or Class III brake test 238.319

Car Body D26 Ensure chlorinator has 1 tablet. Verify lid and gasket are secure. Lubricate Gasket. 229.139 D27 Check operation of toilet for correct timing and presence of water. 229.137 D28 Verify water level, top off as necessary D29 Verify distance between coupler guard arm and knuckle nose does not exceed 5-1/8” 229.61(a)(1) D30 Verify coupler head, shank, and components free of cracks, breaks, and bends. 229.61(a)(2) D31 Verify cut levers are not bent or broken and are free from obstruction.

D32 Verify cut levers are secured in down (locked) position with coupler locked.

D33 Verify lock lift assy has proper rod eye clearance with coupler locked and centered.

D34 Verify telltale recess and/or telltale hole are fully visible with coupler fully locked. 238.303(e)(3) D35 Verify slack in the coupler or drawbar not absorbed by friction devices or draft gears does not exceed ½” 229.61(a)(4) D36 Verify coupler carrier is not cracked or broken. 229.61(a)(5) D37 Verify coupler yoke is not broken or cracked. 229.61(a)(6) D38 Verify coupler draft gear is not broken. 229.61(a)(7) D39 Verify a device is provided under the drawbar pins to prevent the pin from falling out in case of breakage 229.61(b) D40 Verify security of generator access, fuel access, battery access and all other access doors on outside of vehicle D41 Verify that no parts except wheels and sander hoses are less than 2 ½ inches above the rail. 229.71

Electrical Power and Controls D42 Verify battery voltage at control panel in B6 closet is 24VDC for the generator battery set D43 Verify operation of railroad crossing bells from drivers desks for each end of car D44 Verify operation of horns from drivers desks for each end of car 229.129

D45 Verify operation of headlights, ditch-lights, and marker lights from drivers desks for each end of car 229.125 D46 Verify windshield wiper and washer operation from drivers desk for each end of car D47 Check oil level and antifreeze level of both generator engines D48 Inspect each generator set; wiring, fluid lines, brackets, belt, fan, and overall condition for any defects D49 Check oil level in standby generator D50 Inspect standby generator; wiring, fuel lines, brackets, and mounts for any defects D51 Check generators for unusual noises after engines are started D52 Verify Generator engine monitoring systems from the touch screens on the drivers desks D53 Test speedometer by measured mile post, tachometer, GPS, or equivalent procedure 229.117b D54 Monitor pulse generator and tachometer while moving

Geometry System D55 Perform beam and hardware inspection per ATIP-MN-W002 D56 Check geometry wiring for chafing or breaks and verify instrumentation is mounted securely D57 Clean laser and camera windows on each 3DM sensor head per ATIP-MN-W006

Safety Appliances D58 Verify fire protection system readiness at Aquasys Computer inside closet in bath room D59 Verify flag kit contains red flags and fusees. Each driving desk should have flag kit, blue light and lantern 229.119f D60 Clean windshields 229.119b D61 Verify fault light on event recorder is flashing 0.1 seconds every 6 seconds 229.135(6)©

Suspension D62 Verify that excess lateral in bearing boxes does not exceed 7/16” on each pair of wheels per truck (CFR ¾”) 229.63 D63 Check condition of pneumatic leveling valves and air bags 238.303(e)(5)(vii) D64 Check condition of the end of axle tachometer, earthers, encoder assemblies, pulse generators, and anti-rotation links D65 Inspect truck springs for cracks or breaks and verify that no spring sets are fully compressed 229.65b D66 Inspect truck shocks and shock mounting hardware 229.65c D67 Inspect truck frame and truck components for cracks or breaks especially in stress areas of the truck 229.67c D68 Verify wheels are free from defects per 49 CFR 229.75 and 229.73 D69 Verify any wheel flat spots, shelling, and spalling do not exceed 1.5” in length. [CFR 2½”]229.75(a,d) D70 Verify chips or gouges in wheel flange do not exceed 1.5” in length and .5” in width. 229.75(b) D71 Verify lengthwise wheel tread seams or grooves are not within 3 ¾” of the flange or ⅛” or more in depth. 229.75(e) D72 Verify wheel flange thickness is not 1” or less.[CFR ⅞”] 229.75(f) D73 Verify wheel tread worn hollow does not exceed 5/32” [CFR 5/16”] 229.75(g) D74 Verify wheel flange height is not 1 ⅜” or greater. [CFR 1½”] 229.75(h) D75 Verify wheel rim thickness is not 1 1/16” or less. [CFR 1”] 229.75(j) D76 Verify wheels do not have cracks or breaks in the flange, tread, rim, plate, or hub 229.75(k) D77 Verify wheel set does not have a scrape, dent, gouge, or grooved tread 1/8” or greater depth.

D78 Verify wheels do not show evidence of overheating or discoloration on front and back of plate that extends 4” into

D79 Verify wheels are not loose or have any welds. 238.303(e)(8) D80 Verify axle is not cracked, broken, or bent. 238.303(e)(8)

DOTX-217 Weekly Maintenance Checklist

Task Maintenance Objective Complete Complete other inspections

W1 Perform Daily Inspections and complete inspection checklist Propulsion

W2 Inspect and clean #1 Drive Engine Turbo Air Charger W3 Inspect and clean #2 Drive Engine Turbo Air Charger W4 Drain #1 Drive Engine Fuel/Water separator W5 Drain #2 Drive Engine Fuel/Water separator

W6 Determine hours since last service for each drive engine. Perform periodic maintenance as appropriate DE1 Current Hours: Hours at last service: Hours Since Last Service:

DE2 Current Hours: Hours at last service: Hours Since Last Service:

Braking W7 Inspect Brake pad wear, verify brake pads have minimum 3/8’s inch pad material remaining in center of pad W8 Perform weekly Brake/Air System check, record all results on Brake Test Form ATIP_MN_FORMS_008 W9 Clean AZ7 and AZ15 Brake Indicators on outside of vehicle

Electrical Power and Controls W10 Drain #1 Generator Engine Fuel/Water separator W11 Drain #2 Generator Engine Fuel/Water separator

W12 Determine hours since last service for each generator. Perform periodic maintenance as appropriate GE1 Current Hours: Hours at last service: Hours Since Last Service:

GE2 Current Hours: Hours at last service: Hours Since Last Service:

W13 Determine hours since last service for standby generator. Perform periodic maintenance as appropriate SGE Current Hours: Hours at last service: Hours Since Last Service:

W14 Inspect forward truck traction link center pin and ensure pin is seated properly W15 Inspect rear truck traction link center pin and ensure pin is seated properly

DOTX-217 Periodic Generator Maintenance at Oil Change Intervals of 250 hrs

Generator: #1 Engine Hours:

Task Maintenance Objective Complete GE1-1 Clean Generator cooling air intake screens GE1-2 Change Engine Oil GE1-3 Change Oil Filter GE1-4 Change Air Filter GE1-5 Change Fuel Filters GE1-6 Wipe down generator, engine and frame

Generator: #2 Engine Hours:

Task Maintenance Objective Complete

GE2-1 Clean Generator cooling air intake screens GE2-2 Change Engine Oil GE2-3 Change Oil Filter GE2-4 Change Air Filter GE2-5 Change Fuel Filters GE2-6 Wipe down generator, engine and frame

DOTX-217 Periodic Standby Generator Maintenance at Oil Change Intervals of 100 hrs

Generator: Standby Engine Hours:

Task Maintenance Objective Complete SGE-1 Change Engine Oil (Requires 15W40 Synthetic for diesel engines) SGE-2 Clean Engine Oil Filter SGE-3 Wipe down generator, engine and control panel

DOTX-217 Monthly Maintenance Checklist

Task Maintenance Objective Complete Complete other inspections

M1 Perform Daily and Weekly Inspections and complete inspection checklists Propulsion

M2 Inspect Drive Engine 1 alternator belts for damage and tightness M3 Inspect Drive Engine 2 alternator belts for damage and tightness M4 Lubricate anti-rotational links M5 Verify that Transmission 1 Pall Fine filter has not popped

M6 Inspect overall condition of Transmission 1 for loose or missing hardware, chafed wiring or fluid lines, and external damage

M7 Verify that Transmission 2 Pall Fine filter has not popped

M8 Inspect overall condition of Transmission 2 for loose or missing hardware, chafed wiring or fluid lines, and external

M9 Inspect overall condition of Drive Engine 1 coolant and hydraulic systems. Look for loose plumbing fittings or leaks, Inspect for loose or missing hardware, chafed wiring or fluid lines, and any external damage

M10 Inspect overall condition of Drive Engine 2 coolant and hydraulic systems. Look for loose plumbing fittings or leaks, M11 Inspect Drive Engine 1 Drive shafts for the compressor, transmission, and gear boxes for excessive wear, damage, and loose or missing hardware

M12 Inspect Drive Engine 2 Drive shafts for the compressor, transmission, and gear boxes for excessive wear, damage, and

M13 Inspect all axle gear boxes for any excessive leaks, loose or missing hardware, or any external damage M14 Inspect Drive Engine 1 Battery Set for overall condition of batteries and treat corrosion where necessary M15 Inspect Drive Engine 2 Battery Set for overall condition of batteries and treat corrosion where necessary

Braking M16 Check Compressor 1 Crankcase oil level and compressor air filter. Change filter if necessary.

M17 Check Compressor 2 Crankcase oil level and compressor air filter. Change filter if necessary.

M18 Drain R118 No-Load Regulator M19 Empty and clean each compressor air dryer white internal strainer and black external cup M20 Check operation of each emergency brake pull handle

Car Body M21 Add one package of MicroCulture to the Microphor waste tank via the toilet M22 Flush chlorinator and downstream plumbing with water. Ensure proper drainage.

M23 Clean all Air Conditioner Air Filters M24 Install new filter elements in the generator door M25 Inspect all passenger seating and seat attachments for anything loose or broken M26 Inspect all luggage racks for anything broken or loose

Electrical Power and Controls M27 Inspect Generator Battery Set for overall condition of batteries and treat corrosion where necessary M28 Inspect Standby Generator battery for overall condition and treat corrosion where necessary M29 Inspect Security System Battery for overall condition of battery and treat corrosion where necessary M30 Inspect AC and DC PLC batteries using the Concept Program on the Utility Laptop

Geometry System M31 Record all geometry system computer software versions M32 Record all geometry system gains

Safety Appliances M33 Inspect flags, flag stands, derails, locks, and chocks. Apply high visibility paint if necessary.

M34 Ensure latest version of maintenance checklists and forms are stored on General Purpose and restock checklist binder

M35 Record Wheel Profiles with MiniProf measurement system M36 Measure Wheels and Complete ATIP-MN-FORMS-011 – AAR Steel Wheel Gage Measurement Form M37 Drain condensation from each Airbag Suspension Tank M38 Verify the 3 bolts under each truck center pin pivot block are secure and safety wired

DOTX-217 Periodic Drive Engine Maintenance at Oil Change Intervals of 250 hrs

Drive Engine: Front Engine Hours:

Task Maintenance Objective Complete

DE1-1 Change Oil, and Oil Filters DE1-2 Replace Fuel Filters DE1-3 Coolant Additive, pH (NTE 9.5) DE1-4 Coolant Antifreeze, Freeze pt (50/50 = -34) DE1-5 Coolant Pre Charged Filter, Nitrates– (1200 ideal) DE1-6 Change inner and outer Air Filters DE1-7 Change coolant Filters

Drive Engine: Rear Engine Hours:

Task Maintenance Objective Complete

DE2-1 Change Oil, and Oil Filters DE2-2 Replace Fuel Filters DE2-3 Coolant Additive, pH (NTE 9.5) DE2-4 Coolant Antifreeze, Freeze pt (50/50 = -34) DE2-5 Coolant Pre Charged Filter, Nitrates – (1200 ideal) DE2-6 Change inner and outer Air Filters DE2-7 Change coolant Filters

DOTX-217 Quarterly Maintenance Checklist

Task Maintenance Objective Complete

Complete other inspections Q1 Perform all Daily through Monthly inspections and complete checklists

Propulsion Q2 Inspect #1 Drive Engine Vibration Damper Q3 Inspect #2 Drive Engine Vibration Damper

Q4 Lubricate all drive shafts on the #1 Drive Engine Drive Line including; Compressor, Transmission, Main, and Intermediate

Q5 Lubricate all drive shafts on the #2 Drive Engine Drive Line including; Compressor, Transmission, Main, and

Q6 Replace both Racor filter elements Car Body

Q7 Change oil in electric air compressor Q8 Change air filter on electric air compressor

Electrical Power and Controls Q9 Perform Uninterrupted Power System (UPS) automated battery test

Q10 Verify Emergency lighting systems are in place and operational Q11 Replace fuel filter for standby generator engine Q12 Replace air filter for standby generator engine Q13 Replace oil filter for standby generator engine Q14 Adjust clearance of intake and exhaust valves on standby generator (Clearance should be 0.006” – 0.008”) Q15 Clean all DB9 and CAT 5 connectors for the PLC control modules

Geometry System Q16 Perform Geometry System calibration Q17 Perform beam and hardware inspection per ATIP-MN-W002

Safety Appliances

Q18 Verify all mechanical systems and components of the equipment are free from any discrepancies that may endanger

Q19 Clean all smoke detectors

Q20 Verify all trucks are equipped with a device or securing arrangement to prevent the truck and car body from separating

Q21 Verify all center castings on trucks are not cracked or broken, to the extent possible without jacking the car and rolling

DOTX-217 Annual Maintenance Checklist

Task Maintenance Objective and 49 CFR Reference Complete Items to complete before car arrives Schedule Cummins Technician to come out to car to check and adjust overheads on both Drive and Generator Engines Verify that all pneumatic system filters are on hand Verify that hydraulic system filters are on hand Verify that alternator belts are purchased and on hand Purchase fluids needed for maintenance including; Hydraulic, transmission, compressor, gear box gear oil, antifreeze Arrange PC-1 Inspection Complete other inspections

A1 Perform all Daily through Quarterly inspections and complete those checklists Propulsion System

A2 Remove Drive Engine #1 belly pan and inspect engine wiring, starter and starter wiring, alternator wiring, and all fluid lines

A3 Clean Drive Engine #1 crankcase breather (Replace if Damaged) A4 Inspect/tighten engine mounting bolts for #1 Drive Engine A5 Install new Drive Engine #1 Alternator belts and replace spares that are tied up around the drive shaft A6 Inspect Drive Engine #1 Turbo Charger A7 Inspect Drive Engine #1fuel pump and fuel system lines and hoses for leaks or abrasions

A8 Remove Drive Engine #2 belly pan and inspect engine wiring, starter and starter wiring, alternator wiring, and all fluid

A9 Clean Drive Engine #2 crankcase breather (Replace if Damaged) A10 Inspect/tighten engine mounting bolts for #2 Drive Engine A11 Install new Drive Engine #2 Alternator belts and replace spares that are tied up around the drive shaft A12 Inspect Drive Engine #2 Turbo Charger A13 Inspect Drive Engine #2 fuel pump and fuel system lines and hoses for leaks or abrasions A14 Have both Drive Engine End Crank Clearances checked by Cummins service technician A15 Have both Drive Engine overheads adjusted by Cummins service technician A16 Have both Drive Engine fuel injectors inspected, cleaned, and tested by Cummins service technician A17 Inspect both Voith roof mounted radiators, verify that there are no leaks and that the cooling fins are not damaged A18 Inspect #1 Drive engine cooling system lines and intercooler mounted on the underside of the car A19 Inspect #1 hydraulic drive on the #1 Transmission for any leaks, cracks, and loose or missing hardware A20 Clean #1 hydraulic tank fill screen under fill cap, install new system return filter and change fluid A21 Inspect #2 Drive engine cooling system lines and intercooler mounted on the underside of the car A22 Inspect #2 hydraulic drive on the #2 Transmission for any leaks, cracks, and loose or missing hardware A23 Clean #2 hydraulic tank fill screen under fill cap, install new system return filter and change fluid A24 Change gear oil in each Axle Gearbox

Braking System A25 Perform annual brake maintenance per ATIP-MN-W008 A26 Inspect all brake caliper units and brake discs for any cracks, breaks, or other discontinuities A27 Change #1 compressor crankcase fluid A28 Change #2 compressor crankcase fluid A29 Inspect forward trucks brake rigging, lines, hoses and clamps for tightness and security A30 Inspect rear trucks brake rigging, lines, hoses, and clamps for tightness and security A31 Inspect end of car brake and main line hoses. Replace if damaged or more than 7 years old A32 Update Air Brake Maintenance Record ATIP_MN_FORMS_015 to reflect brake system changes

Car Body A33 Pressure wash roof of car and roof mounted equipment, outside body, and underside of car A34 Inspect, clean, and lubricate entryway IFE automatic plug doors A35 Test the manual release of each plug door for proper operation A36 Inspect condition of Microphor toilet hopper and flapper seals A37 Inspect Microphor biological waste treatment tank, lines to and from the tank, and system chlorinator A38 Have Microphor biological waste treatment tank pumped and flushed out

A39 Inspect all generator engine wiring, connections, and terminations A40 Inspect generator engine fuel pump, fuel system lines and fuel hoses for leaks or abrasions A41 Inspect generator engines water pumps and radiator hoses

A42 Inspect each generator engine radiator for clogging at the radiator fins. Remove and have professionally cleaned if necessary

A43 Inspect each generator engine serpentine belt, vibration damper, alternator, and belt tensioner A44 Have each generator engine serviced by Cummins Service Tech to inspect and adjust engine overhead and injectors A45 Inspect generator body and wiring for loose connections and overall tightness A46 Clean each generator control board and circuit protection devices under top access panels.

A47 Change one main battery set for the drive/generator engines each year and write on outside of battery set the change date.

A48 Install new PLC gel cell batteries in the B6 closet floor A49 Install new security system battery in the B6 closet floor A50 Install new AC control relay PLC battery A51 Install new DC control relay PLC battery A52 Inspect each HVAC unit on the roof of the vehicle for noticeable flaws, wear, or damage A53 Clean and inspect the evaporator and condenser coils on each HVAC unit on the roof of the vehicle A54 Thoroughly clean or replace the inside air filters on each HVAC unit A55 Check operating pressures in each HVAC unit

Geometry System A56 Remove all geometry system sensors and test equipment used for system calibration and ship in for calibration A57 Clean all geometry system computer air filters

A58 Upon receiving geometry system sensors and test equipment back from calibration verify each component has the

A59 Inspect geometry beam and mounting components per ATIP-MN-W002 A60 Replace exterior lenses in each 3DM sensor head A61 Perform reproducibility evaluation per ATIP-MN-08

Safety Appliances A62 Have annual inspection done on all fire extinguishers A63 Inspect and update first aid kit A64 Inventory and update vehicle flagging kit A65 Update inventory of blue lights A66 Update inventory of safety vests, hard hats, safety glasses, and ear plugs.

A67 Have PC-1 Inspection conducted A68 Verify activity on all event recorder channels within the last 48 hours of operation 229.27(d)(2)

Suspension

A69 Perform “Plain Inspection” of truck bogies per Plasser Theurer Manufacturer’s Maintenance Scheme for EMA61.27A bogies

A70 Remove one sample of each type of shock and test compression/expansion A71 Install new Plate 16 primary suspension airbag air filter I34851 A72 Have wheel gauges calibrated. File calibration certificates on the server.

DOTX-217 2 -Year Maintenance Checklist

Task Maintenance Objective Complete Propulsion

2-1 Change Coolant and Pre Charged Filters on Front Drive Engine 2-2 Clean and Calibrate Injectors on Front Drive Engine 2-3 Clean Injector Screen on Front Drive Engine 2-4 Inspect Turbocharger on Front Drive Engine 2-5 Check Viscous Vibration Dampers on Front Drive Engine 2-6 Inspect Water Pump on Front Drive Engine 2-7 Change Coolant and Pre Charged Filters on Rear Drive Engine 2-8 Clean and Calibrate Injectors on Rear Drive Engine 2-9 Clean Injector Screen on Rear Drive Engine

2-10 Inspect Turbocharger on Rear Drive Engine 2-11 Check Viscous Vibration Dampers on Rear Drive Engine 2-12 Inspect Water Pump on Rear Drive Engine

Braking

2-13 Perform COT&S on half the car per ATIP-MN-W008. Alternate halves so all components have COT&S of less than 4 years

2-14 Inspect / Change Brake Pads

2-15 Inspect Trucks per Manual Section 5

DOTX-217 3 -Year Maintenance Checklist

Task System Maintenance Objective Complete 3-1 Propulsion Change Oil and Filters in Front Transmission 3-2 Propulsion Change Oil and Filters in Rear Transmission 3-3 Car Body Clean/ Grease/ Maintain Sliding Door Spindles and Cylinders per manual 3-4 Elec. Power and Controls Replace cranking battery for standby generator

DOTX-218 DAILY MAINTENANCE CHECKLIST

Rev: 10 Effective: 6/27/12

Site: Date: RR: Odometer: Avg Temp:

Signature after completion of Class I Brake Test: Time:

Task Maintenance Objective and 49 CFR Reference Complete Propulsion

D1 Verify drive engine cranking battery voltage on the LCD on the driving desk is 24VDC D2 Verify fuel level, top off as necessary D3 Verify safety hangers on trucks, propeller shafts, and journal boxes are in place 229.65(a); 229.67(b); 229.99 D4 Check Drive Engine oil level, alternator belts, external wiring, fluid lines and overall condition for any defects D5 Check coolant level of drive engine at reservoir on the roof of the car. Should be in the middle of sight glass D6 Check transmission fluid level D7 Check axle gear box oil levels in both units on the forward truck D8 Check transmission gear box declutch mechanism for proper position D9 Check oil level of Voith hydraulic tank reservoir

D10 Check drive engine for unusual noises after engine is started D11 Monitor all driving desk indicated conditions while in operation D12 Verify Drive Engine monitoring systems function properly 229.101a

Braking D13 Verify slip-slide system shows no faults 229.115 D14 Drain all water separators, air reservoirs, centrifugal filters, and drip cans 229.131 D15 Verify correct position of all valves for operating mode (self-propelled or towed) D16 After pneumatic system is charged, verify system tightness and that there are no air leaks D17 Check oil level of both air oilers. Main: under front walkway, and Microphor: behind toilet D18 Verify end of car brake hoses are secure D19 Perform initial terminal Class 1 air brake test 232.205 See ATIP-OP-003-W001 D20 Perform Class III brake test if operating end are changed 232.211 See ATIP-OP-003-W002 D21 Perform running brake test as soon as possible after each Class I or Class III brake test 238.319

Car Body D22 Ensure chlorinator has 1 tablet. Verify lid is secure. 229.139 D23 Check operation of toilet for correct timing and presence of water. 229.137 D24 Verify water level, top off as necessary D25 Verify distance between coupler guard arm and knuckle nose does not exceed 5-1/8” 229.61(a)(1) D26 Verify coupler head, shank, and components free of cracks, breaks, and bends. 229.61(a)(2) D27 Verify cut levers are not bent or broken and are free from obstruction.

D28 Verify cut levers are secured in down (locked) position with coupler locked.

D29 Verify lock lift assembly has proper rod eye clearance with coupler locked and centered.

D30 Verify telltale recess and/or telltale hole are fully visible with coupler fully locked. 238.303(e)(3) D31 Verify slack in the coupler or drawbar not absorbed by friction devices or draft gears does not exceed ½” 229.61(a)(4) D32 Verify coupler carrier is not cracked or broken. 229.61(a)(5) D33 Verify coupler yoke is not broken or cracked. 229.61(a)(6) D34 Verify coupler draft gear is not broken. 229.61(a)(7) D35 Verify a device is provided under the drawbar pins to prevent the pin from falling out in case of breakage 229.61(b) D36 Verify security of generator access, fuel access, battery access and all other access doors on outside of vehicle D37 Verify that no parts except wheels are less than 2 ½ inches above the rail. 229.71

Electrical Power and Controls D38 Verify the PLC battery voltage on the gauge on the front driver’s desk is 24VDC D39 Verify operation of railroad crossing bells from each driver’s desk D40 Verify operation of horns from each driver’s desks 229.129 D41 Verify operation of headlights, ditch-lights, marker lights, and spot light from each driver’s desk 229.125 D42 Verify windshield wiper and washer operation from each driver’s desk D43 Check oil level and antifreeze level of generator engine D44 Inspect generator set; wiring, fluid lines, brackets, belt, fan, and overall condition for any defects D45 Check generator for unusual noises after engines are started

D46 Verify Generator engine monitoring systems from the control panel D47 Test speedometer by measured mile post, tachometer, GPS, or equivalent procedure 229.117b D48 Monitor pulse generator and tachometer while moving

Geometry System D49 Perform beam and hardware inspection per ATIP-MN-W003 D50 Check geometry wiring for chafing or breaks and verify instrumentation is mounted securely D51 Check condition of laser gage systems for GRMS D52 Check GRMS…