ATTACHMENT_A_-_Dual_Rail_E-Clip_Installer_-_Technical_Specifications.pdf

WMATA

Vehicle Program Services (CENV)

Car Track Equipment Maintenance (CTEM) Technical Specification – E-Clip Applicator – Version-1.2 – 3/26/2019

Preventive Maintenance Manual

Technical Specification

E-Clip Applicator

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Table of Contents

Section/Sub-section Title Page

1 SCOPE

1.1 GENERAL REQUIREMENTS

1.2 WORK TO BE DONE

1.3 MATERIALS

1.4 MICROPROCESSOR HARDWARE AND SOFTWARE

2 SYSTEM DESIGN

2.1 SYSTEM BASIS AND PARAMETERS

2.2 CLEARANCE

2.3 PERFORMANCE REQUIREMENTS

2.4 NOISE AND VIBRATION

2.5 WEIGHT

2.6 RELIABILITY

2.7 MAINTENANCE

2.8 VEHICLE MONITORING AND DIAGNOSTIC SYSTEM

2.9 TESTING REQUIREMENTS

2.10 DELIVERABLES

3 CONSTRUCTION AND ASSEMBLY

3.1 GENERAL

3.2 STRUCTURAL REQUIREMENTS

3.3 UNDERFRAME

3.4 UNDERFRAME EQUIPMENT

3.5 TESTING REQUIREMENTS

3.6 DELIVERABLES

4 UNDERCARRIAGE

4.1 GENERAL

4.2 RIDE QUALITY

4.3 WHEELS AND AXLES

4.4 DERAIL GUARDS

4.5 TESTING REQUIREMENTS

4.6 DELIVERABLES

5 CAB AND CONTROLS

5.1 GENERAL

5.2 ARRANGEMENT

iv V-1.2 – E-Clip Applicator – Technical Specification

5.3 CAB WINDOWS

5.4 HVAC

5.5 CAB EQUIPMENT

5.6 CAB CONTROLS AND INDICATIONS

5.7 CAB WATER LEAKAGE TEST

5.8 TESTING REQUIREMENTS

6 DIAGNOSTIC SYSTEM

6.1 DIAGNOSTICS

6.2 SIGNALS

6.3 SAMPLING AND STORAGE

6.4 DOWNLOAD

6.5 TESTING REQUIREMENTS

6.6 DELIVERABLES

7 ELECTRICAL EQUIPMENT

7.1 GENERAL

7.2 VEHICLE GROUNDING

7.3 CIRCUIT BREAKERS

7.4 CABINETS

7.5 BATTERY BOX

7.6 DELIVERABLES

8 PROPULSION AND HYDRAULIC EQUIPMENT

8.1 GENERAL

8.2 DIESEL ENGINE

8.3 EXHAUST

8.4 DIESEL EXHAUST FLUID TANK

8.5 AIR COMPRESSOR SYSTEM

8.6 FUEL TANK

8.7 HYDRAULIC SYSTEM

8.8 TESTING REQUIREMENTS

8.9 DELIVERABLES

9 BRAKE SYSTEM

9.1 GENERAL

9.2 BRAKE EQUIPMENT

9.3 BRAKE REQUIREMENTS

9.4 TESTING REQUIREMENTS

10 COMMUNICATIONS

10.1 RADIO

10.2 CAMERA

10.3 TESTING REQUIREMENTS

11 LIGHTING SYSTEM

11.1 EXTERIOR LIGHTING

11.2 INTERIOR LIGHTING

11.3 WORK HEAD LIGHTING

11.4 PERIMETER LIGHTING

11.5 EMERGENCY LIGHTING

11.6 TESTING REQUIREMENTS

11.7 DELIVERABLES

12 WORK TOOLS

12.1 GENERAL

12.2 VISIBILITY

12.3 CONTROLS

12.4 ADJUSTMENTS

12.5 WORK HEAD LOCKS

12.6 ANCHOR ADJUSTER-SPREADER

12.7 WORK HEAD LUBRICATION

12.8 ACCESSORIES

12.9 TESTING REQUIREMENTS

12.10 DELIVERABLES

13 MATERIALS AND WORKMANSHIP

13.1 GENERAL

13.2 FASTENERS

13.3 METAL

13.4 ELECTRICAL SYSTEM

13.5 PAINT

13.6 MARKING

13.7 DELIVERABLES

14 PROJECT MANAGEMENT

14.1 PROJECT MANAGEMENT PLAN

14.2 DESIGN REVIEWS

vi V-1.2 – E-Clip Applicator – Technical Specification

14.3 CHANGE CONTROL

14.4 CONTRACT DELIVERABLES

14.5 DELIVERABLES

15 SYSTEM ASSURANCE

15.1 GENERAL

15.2 RELIABILITY

15.3 MAINTAINABILITY

15.4 REGULATORY REQUIREMENTS

15.5 HAZARD ANALYSIS

15.6 EQUIPMENT PROTECTION, ACCESS, AND MAINTAINABILITY

REQUIREMENTS

15.7 INSPECTION, MAINTENANCE, OVERHAUL, AND MAINTAINABILITY

15.8 LOCKOUT / TAGOUT POLICY

15.9 MAINTAINABILITY DEMONSTRATION

15.10 VISUAL INSPECTION TEST

15.11 TESTING REQUIREMENTS

15.12 DELIVERABLES

16 IN-SERVICE SUPPORT

16.1 MANUALS

16.2 TRAINING

16.3 REPAIR PARTS AND SERVICE

16.4 DRAWING PACKAGE

16.5 DELIVERY AND COMMISSIONING

16.6 TESTING

16.7 WARRANTY

16.8 EQUIPMENT START-UP

16.9 DELIVERABLES

17 APPENDIX

17.1 STANDARD CLEARANCE PACKAGE

Scope – 1

1 SCOPE

1.1 GENERAL REQUIREMENTS

1) This Specification sets forth the requirements for the performance, design, manufacturing, assembly, testing, delivery, and acceptance of E-Clip Applicator (hereunder referred to as the “Unit”). In addition, this Specification includes requirements concerning program management, compliance demonstration, product support, and data submittal.

2) This Specification is generally complete and comprehensive but is not intended to describe all work details to be performed and therefore must be supplemented by the Contractor's experience in building rail work equipment, on its examination of the WMATA system, and on its detailed design, manufacturing and testing capabilities.

3) Training of WMATA’s staff in the operation and maintenance of the Unit and full supporting documentation for training programs shall be provided. Refer to Section 16.

4) The Contractor shall provide after-sales service support with factory trained service technicians to assist in start-up and training.

5) The Contractor shall provide a list of optional equipment that is not identified within this Specification but which the Contractor feels would be beneficial for WMATA to have in order to operate or maintain the Unit. The unit price for each optional piece of equipment shall be provided along with the Offeror’s proposal.

6) The Unit shall comply and conform to all Federal, State, and Local (D.C., MD-including Price George’s and Montgomery County and VA-including Arlington, and Fairfax Counties, the Cities of Alexandria and Falls Church) environmental, safety, and health regulations in force at the time of delivery.

7) Upon completion of manufacture and before any operation begins, all parts shall be clean and free from scale, rust, water, and/or any contamination. All materials and workmanship must be of adequate quality for the intended use.

8) References to commercial and industrial standards, specifications, and recommendations, whether stated or not stated as the latest revision, pertain to the version in effect at the time of the proposal, unless specifically indicated otherwise.

9) The following list of applicable standards referred to in this Specification:

• ASTM-A-325 Standard

1 – Scope

2 V-1.2 – E-Clip Applicator – Technical Specification

• ISO 16889 Standard

• 49 CFR 214.511

• MIL-HDBOOK-1472 Human Engineering Design

• Society of Automotive Engineers SAE-Y-24A Standard

• Society of Automotive Engineers SAE-J-1003 Standard

• Society of Automotive Engineers SAE-J-1243 Standard

• Society of Automotive Engineers SAE-J-10-B Standard

• Society of Automotive Engineers SAE 100 Standard

10) References to sections within this Specification are provided for convenience.

If errors exist, or references are incomplete, the Contractor shall bring these issues to WMATA's attention, in writing, for clarification.

11) If at any time the Contractor finds that any requirement of this Specification appears to be in error or in conflict with the general intent of this Specification, then it shall immediately bring the apparent problem to WMATA's attention, in writing. WMATA will determine whether or not the Specification needs to be modified.

12) The Contractor is solely responsible for the detailed design of the Unit and shall furnish a Unit, which is in all respects compliant with this Specification in a manner which is consistent with the best engineering and construction practices.

13) After Contract award, the Contractor shall not be entitled to excusable delay or additional compensation for errors or incomplete references in this specification or conflicts with the general intent of this specification unless the Contractor had brought such issue to the attention of WMATA in writing prior to Contract award and WMATA failed to take appropriate corrective action.

1.2 WORK TO BE DONE

1) The Unit to be furnished and delivered under this Contract shall be appropriate for use on WMATA's rail system. This Specification sets forth the performance requirements for the Unit.

Scope – 1

2) The Unit, as herein specified, shall be delivered to a location on WMATA property as designated by Section 16.4.

3) The Contractor shall submit documentation (drawings, analyses, calculations, etc.) with detailed technical information in order to demonstrate specification compliance. WMATA's review, comments, or approval will not relieve the Contractor of his sole responsibility for the Unit's design. The Contractor shall submit additional documentation as required by WMATA as part of its review.

The Contractor shall submit a list of all items that are considered proprietary equipment and off-the-shelf items with the Proposal, and the list shall be updated, monthly, beginning thirty (30) days after the Notice of Award date.

1.3 MATERIALS

1) Materials for the construction of the Unit shall be selected to obtain the maximum strength and reliability balanced against minimizing weight consistent with the Specification. All parts shall be of a sufficiently robust design and implementation to survive the environment and operation described herein. The components expected to withstand extensive handling include control handles, door latches, key switches, knobs, and buttons.

2) The Unit shall be free from defects such as incomplete welds, welds that cross welds, corrosion, lose or improper fasteners, any leaks or contamination, and any other defects that would impair or limit the operation or serviceability. All welds must comply with the associated American Welding Society (AWS) standards.

3) All materials and equipment furnished by the Contractor shall be new and shall be subject to inspection and Approval by WMATA. However, it shall be the Contractor's full responsibility for inspection and quality of material and workmanship (see Section 13).

1.4 MICROPROCESSOR HARDWARE AND SOFTWARE

1) WMATA requires that sophisticated, professional, and appropriate systems be provided to meet all control and data processing needs. Detailed documentation regarding the various hardware and software systems provided on the Unit, including description of control philosophies and control algorithms, shall be submitted for approval. This effort will require the Contractor to provide high levels of technical management and design coordination to the various sub suppliers of microprocessor-based equipment.

The Contractor shall dedicate experienced staff who are knowledgeable regarding state-of-the-art applications of microprocessor hardware and software in real time control systems.

1 – Scope

4 V-1.2 – E-Clip Applicator – Technical Specification

2) Microprocessor-based control systems shall be highly integrated to eliminate undesired redundant hardware and software, while providing optimum functionality and diagnostics.

3) All non-proprietary codes shall be provided to WMATA. All PLC logic trees shall be provided.

4) Software changes shall be covered by the Contractor under warranty.

System Design – 2

2 SYSTEM DESIGN

2.1 SYSTEM BASIS AND PARAMETERS

2.1.1 General

1) This Section establishes the functions, Subsystem performance, and general design criteria for the Unit. Included are requirements for configuration, capacity, dimensions, performance, operating environment, environmental parameters, noise and vibration, weight, and other requirements that impact System and Subsystem design.

2) The Unit shall be designed to have a minimum service life of ten (10) years.

The achievement of design life assumes compliance with WMATA maintenance intervals and assumes WMATA maintenance and operating practices. The duty cycle of the Unit is defined as continuous operation for 12 hours, and up to 4500 hours per year.

3) The Unit shall be equipped with an approved power plant, brake equipment, HVAC System, communication system, work heads and such other equipment as specified herein.

4) The Unit shall be capable of operating under all exterior ambient conditions as specified in Section 2.1.4. Heat generated by E-Clip Applicator equipment shall be taken into consideration in the design.

2.1.2 Arrangement

1) The Unit shall be equipped with a climate controlled, fully enclosed cab.

2) The power plant shall be completely covered by a roof and wall structure.

3) The unit shall be equipped with work heads, one over each rail, to allow simultaneous installation of all four clips on a tie.

4) The unit shall be equipped with controls for propulsion and braking.

5) Both ends of the unit shall be equipped with tow pad eyes (Refer to Section 3.1.2).

6) The unit shall be equipped with an integral, hydraulically operated, rail to rail turntable (Refer to Section 3.3.1).

2.1.3 Operating Physical Environment

2 – System Design

6 V-1.2 – E-Clip Applicator – Technical Specification

1) The Unit shall be suitable for use on WMATA's multiple track infrastructure as described by the following data:

Feature Dimension/Criteria

Rail 115 RE Canted 1:40 Minimum radius of track curve 225 ft.

Minimum length of tangent between reverse curves

13 ½ ft.

See Note 1

Shape of vertical curves Parabolic

Minimum length of vertical curves 200 ft.

See Note 2

Maximum grade 5%

Most restrictive crossover No. 6 with 14 ft. track centers

Maximum super elevation 6 in.

Gauge, tangent track and curves with radii of 1,425 feet and greater 4 ft. 8-1/4 in.

Gauge, tangent track and curves with radii of between 350 and 1,425 feet 4 ft. 8-1/2 in.

Radius less than 350 feet with restraining rail 4 ft. 9-1/4 in.

Maximum track cross level 6 in.

Note 1: The most severe reverse-curve situation is that in which two guarded No. 6 turnouts (of the same hand) face each other with 13.53 feet of tangent track between the points and 250-foot radius curves (in the same direction as the turnout) that continue beyond both frogs.

Note 2: The minimum length of vertical curve is determined by the formula L = (G1 - G2) 100 where L = Length in feet and (G1 - G2) = Algebraic difference in grade in percent. No vertical curve will be less than 200 feet long.

2.1.4 Exterior Ambient Conditions

1) The Unit and all related equipment shall be capable of operating at the specified performance levels under the anticipated climate conditions listed below.

a) Annual Atmospheric Temperature range: -5° F to 105° F

b) Maximum Rainfall: 12” in 24 hours.

c) Maximum Snowfall: 23” in 24 hours.

d) Glaze or Freezing Rain: Three times per year

e) Number of thunderstorm days per year: 18 average.

f) Fog: Heavy salt air fog is common throughout the WMATA System.

2.2 CLEARANCE

1) Equipment must be capable of negotiating all WMATA track, tunnels, and structures and stay within the dynamic envelope as depicted in the “WMATA Rapid Transit Car Clearance Envelope” and “METRO Rapid Transit Car – Dynamic Outline, Under Floor Car Clearance” clearance diagrams in Appendix.

2) Equipment must conform to all WMATA restrictions regarding height, width, and weight. Specifications and drawings are provided in the Appendix of this contract detailing height, width, and weight.

3) The Unit and appurtenances shall successfully operate and negotiate within the constraints of the physical structures of the WMATA System. The following drawings define the guide way constraints (Reference Appendix):

a) “Crane Car Design Loading”

b) ”WMATA Rapid Transit Car Clearance Envelope”

c) ”METRO Rapid Transit Car – Dynamic Outline, Under Floor Car Clearance”

4) Components which may encroach upon track, signal, crossing, or other structures on, or along a railway, shall have a positive mechanical lock to secure these components in a safe position for travel.

5) No Component shall be less than 3" above the plane extending from the ball of one (1) rail to the ball of the other rail with fully worn wheels where applicable.

6) All components which may present a hazard to the operator, assistant, or bystanders shall be protected with a shield or safety device.

7) Handrails or grab irons shall be installed wherever it is intended that personnel board the Unit. The lowest step used for boarding the machine shall not be more than 12" above the top of the running rail unless otherwise approved by WMATA. Any area more than 3 ft. above the top of the running rail (where persons are expected to walk or pass) shall be protected by rigid tubular handrails. The handrails shall be no less than 1-1/4" O.D. diameter, 42" high, 8 V-1.2 – E-Clip Applicator – Technical Specification with a secondary rail 24" high. A 3" kick board shall be provided to prevent entry into potentially hazardous areas

2.3 PERFORMANCE REQUIREMENTS

2.3.1 Travel

1) The Unit shall be capable of travelling up a 6% grade while fully loaded.

Minimum speed when traveling up a 6% grade shall be 10 MPH under dry or wet conditions.

2) The Unit shall be driven and permit operation at maximum speed and fully loaded (at maximum capacity in terms of all tanks full and maximum allowed people on board), in both directions of travel. The power plant shall permit operation under full design load at speeds of not less than 25 mph, on flat tangent track.

3) The Unit shall be capable of operating at a maximum speed of 25 mph without instability or oscillation.

2.3.2 Braking Performance

1) The Unit shall be capable of achieving the minimum brake rates specified in Section 9.3.

2) The braking performance shall be maximized but not result in wheel slide in normal operation.

3) The parking brake shall be capable of holding the Unit on a 6% grade.

2.4 NOISE AND VIBRATION

1) Noise and vibration levels shall not exceed permissible exposure for operators, assistants, and workmen for a continuous eight-hour work day.

2) Noise sources and the machine cab shall be treated to be in total compliance of the following conditions:

a) Less than 90 dBA at 7 ft. from the power plant housing and less than 85 dBA at 50ft. from the centerline of the track, or comply with MIL-HDBK- 1472, Human Engineering Design.

b) Interior cab noise shall never exceed 80 dBA with cab doors and windows closed.

2.5 WEIGHT

1) The Units shall have a maximum weight limit of 25,000 lbs. wet.

2.6 RELIABILITY

1) The Unit design, construction, and materials used shall ensure that it will function reliably and efficiently in sustained operations under harsh and extreme conditions in adverse railway environments.

2.7 MAINTENANCE

2.7.1 General

1) The Unit shall incorporate a design which allows ease of access, service, replacement, and adjustment by maintenance and operational personnel including filters, fluids, and other components.

2.7.2 Special Tools

1) The Contractor shall supply one set of special tools if required for service or repairs, along with four (4) sets of diagnostic equipment necessary to evaluate the overall functionality of the complete operating system of the vehicle to include all OEM engine and transmission systems (CDRL 02-01).

2.8 VEHICLE MONITORING AND DIAGNOSTIC SYSTEM

2.8.1 General

1) The Contractor shall provide a Vehicle Monitoring and Diagnostic System (VMDS). The objective of the VMDS is to improve vehicle maintenance efficiency by storing faults and other data useful for maintenance and troubleshooting activities. A failure in the VMDS or its wiring shall not cause a fault in another system. The proposed VMDS design must be submitted for WMATA approval (CDRL 02-02).

10 V-1.2 – E-Clip Applicator – Technical Specification

2.9 TESTING REQUIREMENTS

Test Description

Section Reference

Qualification Test, at Contractor Location

Pre Shipment Test, at Contractor

Location Conformance Test, at WMATA Location

Acceptance Test, at WMATA Location

System Clearance

Checks (within the WMATA system)

2.2 X

Minimum Speed on Grade 2.3.1.1) X

Maximum Speed 2.3.1.2) X

Parking Brake Holds on 6%

Grade 2.3.2.3) X

Noise Level Measurements 2.4.2) X

2.10 DELIVERABLES

CDRL Reference Deliverable Timing 02-01 2.7.2.1) Special Tools Vehicle Delivery 02-02 2.8.1.1) Proposed VMDS Design 15 Days prior to

Design Presentation

Construction and Assembly – 3

3 CONSTRUCTION AND ASSEMBLY

3.1 GENERAL

3.1.1 Lifting Points

1) The Unit shall be provided with a means of lifting it with a crane hook without damage to any equipment.

2) Lifting points and balance points must be clearly marked and labeled.

3) The Unit shall come equipped with designated tie-down points, jack pads, and all rigging required designed for loading and unloading the equipment on a flatbed truck and shall be stowed in an accessible area on the Unit.

3.1.2 Towing

1) One (1) tow eye of 2 1/8" in diameter shall be provided at each-end of the Unit.

The tow eye shall be 14", +/- ½”, from the top of rail to centerline of tow eye as measured with new wheels. Refer to Appendix 17.1.5 for reference documents.

2) One (1) tow bar with 2" pins of a strength equal to 150% of the Draw Bar force required by the maximum load coupled to the Unit, of six (6) foot length (or longer if required) and shall be provided and stowed in an accessible area of the Unit. Tow bar shall be rated and labeled at minimum 25,000 lbs. Refer to Appendix for reference documents.

3.2 STRUCTURAL REQUIREMENTS

1) As a method of demonstrating that the structure is fit for its intended purpose, the Contractor shall meet the following requirements. Alternatively, the Contractor may offer evidence of a proven service history on systems similar to WMATA, subject to WMATA approval (CDRL 03-01).

a) Design of structural members subject to normal working loads shall have a minimum design safety factor of 2 to 1.

b) Structural members shall be designed to withstand impact stresses with a minimum safety factor of 3 to 1.

c) It is generally recognized that these are only a minimum recommended guideline and greater design safety factors may be required as necessary.

3 – Construction and Assembly

12 V-1.2 – E-Clip Applicator – Technical Specification

3.3 UNDERFRAME

3.3.1 Turntable

1) Unit shall be equipped with a hydraulic turntable that will allow clearance of the third rail when turning unit.

2) The turntable must maintain unit level during process and shall have a positive lock for travel mode.

3) Warning lights and buzzer shall be equipped indicating turntable in use.

3.4 UNDERFRAME EQUIPMENT

1) No hanging loads are permitted. Underframe equipment shall be safety mounted such that failure of mounting hardware will not allow components to fall to the roadbed.

2) As an alternative, equipment may be equipped with safety straps.

3) Driveshafts shall have safety loops.

3.5 TESTING REQUIREMENTS

Test Description

Section Reference

Qualification Test, at Contractor Location

Pre-Shipment Test, at Contractor

Location Conformance Test, at WMATA Location

Acceptance Test, at WMATA Location

Functional Demonstration of Turntable

3.3.1 X

3.6 DELIVERABLES

03-01 3.2.1) Documentation of Service Proven Design or

Stress Analysis Results 15 Days prior to

Undercarriage – 4

4 UNDERCARRIAGE

4.1 GENERAL

1) The undercarriage shall be of a service proven design that meets the requirements herein.

4.2 RIDE QUALITY

No excessive vibration, wobble, or eccentric action shall occur at any speed for which the unit is intended. Unit design shall provide for damage-free operation under maximum foreseeable operating stresses. The entire machine shall withstand a free drop of 6 inches to a non-resilient surface without permanently impairing normal travel or operating functions.

4.3 WHEELS AND AXLES

4.3.1 Wheels

1) Wheel gauge to fit standard track gauge of 56-1/2 inches.

2) Diagonal measurements shall be within tolerance of AREMA Manual for Railway Engineering Chapter 27, Section 2.1.4.e:

+/-1/8” maximum tolerance for wheelbases up to 9 ft.

+/- 3/16” maximum tolerance for wheelbases greater than 9 ft.

3) Wheels shall be hub mounted, forged steel and shall conform to the following material requirements:

a) Conform to AAR Wheels Carbon Steel Specification M-107/M-208.

b) Uniformly austenitize then quench rims. Charge in furnace and cool under controlled conditions for tempering to meet heat treat requirements of AAR Class C hardness (321-363 BHN) to a minimum depth of 3/8 inches.

c) AAR-1B wide flange profile, 1:17-1:23 taper.

4) Wheel diameter shall be minimum sixteen (16) inch.

5) Wheel profile shall be AAR 1B wide or WMATA approved.

6) Axle assembly dimensional drawings, including back to back dimension, shall be supplied to WMATA for approval prior to assembly (CDRL 04-01).

4 – Undercarriage

14 V-1.2 – E-Clip Applicator – Technical Specification

7) Wheels shall be pressed in accordance with the AAR Wheel and Axle Shop Manual, G-II, latest edition. All press records shall be provided for WMATA review (CDRL 04-02).

4.3.2 Axles

1) The Unit shall be equipped with two (2) axles.

2) The axles shall be three (3) inch minimum diameter and suitably attached to achieve safe travel at maximum operating conditions of FRA Class 3 track profile.

3) All axle bearings shall be solid pillow block and designed for a 250,000 mile service life.

4) The Unit axles shall not be insulated. The Unit shall not be converted from an insulated design by bonding around insulating parts. If a shunt bond is used, its design must be approved by WMATA. The Unit shall give a positive indication of track occupancy under any condition of loading. The Unit wheel-to-wheel impedance of each wheel axle assembly shall be less than 0.2 ohms when measured with a 100 volt source over the frequency range of 1 to 10 kilohertz.

4.4 DERAIL GUARDS

1) Derail guards shall be incorporated near each wheel to cover inboard and outboard rail area, so that in the event of derailment, the machine shall not leave the rail. The derail guards shall be designed to prohibit any part of the Unit from touching the contact rail at any time. (Reference Appendix for dimensions.)

4.5 TESTING REQUIREMENTS

Test Description

Section Reference

Qualification Test, at Contractor Location

Pre Shipment Test, at Contractor

Location Conformance Test, at WMATA Location

Acceptance Test, at WMATA Location

Stable Ride Quality at Max

Speed 4.2.1) X

Wheel-to-wheel Impedance 4.3.1.4) X

Undercarriage – 4

4.6 DELIVERABLES

CDRL Reference Deliverable Timing 04-01 4.3.1.6) Axle Assembly Drawings 5 Days prior to

Production 04-02 4.3.1.7) Axle Press Records 5 Days after

Production Begins

5 – Cab and Controls

16 V-1.2 – E-Clip Applicator – Technical Specification

5 CAB AND CONTROLS

5.1 GENERAL

1) A cab shall be provided on the Unit. The cab shall contain all appurtenances necessary for the operation of the Unit.

2) The cab shall be free of sharp edges, protruding objects, safety hazards, and floor obstructions. The cab design shall not include hidden areas in which paper and other debris can accumulate.

3) The cab door shall be equipped with lock hasps which incorporate a 5/8" minimum I.D. hasp ring and be in addition to any other type door locks.

4) If cab insulation is used, it shall be closed foam with perforated metal covering.

Alternatives shall be approved by WMATA.

5.2 ARRANGEMENT

1) The Operator Cab shall provide seating space for two (2) operators.

5.3 CAB WINDOWS

1) The glazing material shall be 1/4" laminated safety glass at a minimum.

2) The windshield wipers shall clear at least 75% of the front and rear glazing, and shall maintain full blade contact with the glazing while the Unit is traveling at maximum speed.

3) All cab windows shall be tinted with visible light transmission of 50%.

4) Adjustable window visors shall be provided to minimize sun glare.

5.4 HVAC

1) The cabin shall have a fully self-contained HVAC unit sized to meet the performance requirements in this section. Red Dot or Visionare are examples of acceptable manufacturers.”

2) Positive pressure shall be maintained with a filtered blower system. Fresh air intakes shall assure a minimum of three (3) changes of air volume per hour.

3) The heating system shall be sized to maintain an interior temperature of at least 68° F.

Cab and Controls – 5

4) The cooling system shall be sized to maintain an interior temperature of at least 78° F.

5) Front and rear windows shall be equipped, at a minimum, with defrosting fans to ensure 80 percent viewing area free of frost and fog.

6) Forced air defrost mechanism may be proposed for approval.

5.5 CAB EQUIPMENT

5.5.1 Seats and Visibility

1) Two (2) Operator seats shall be constructed of durable non-toxic materials.

2) The operator seat position shall be equipped with a cushioned seat and back, employing natural or man-made leather, over 3" low smoke foam cushion or WMATA approved equal.

3) The operator’s seat shall have a seat belt.

4) The operator seat position shall be adjustable to accommodate operators ranging in height from 5'2" to 6'4".

5) The seat, and its moving parts, shall not contact other components through its entire range of motion.

6) The seat shall be placed in the cab to allow an unrestricted view of the front and rear of machine.

7) Rear view mirrors shall be installed on both sides of the machine.

8) A front and rear, color, high definition, camera system shall be installed on the machine. The video shall be recorded on a secure Digital Video Recorder (DVR), designed specifically for use in heavy rail and mass transit applications.

a) DVR shall incorporate security features such that it cannot be turned off and video cannot be deleted or modified by unauthorized personnel.

b) The DVR shall be locked with two (2) keys per Unit.

9) Foot rests shall be installed for crew seats in front of and adjacent to lower cab windows and shall protect windows from damage.

5.5.2 Fire Extinguisher

1) Cab shall include a five (5) LB dry type fire extinguisher, securely mounted in plain sight of Operator, and an ANSI Class A first-aid kit.

18 V-1.2 – E-Clip Applicator – Technical Specification

5.6 CAB CONTROLS AND INDICATIONS

5.6.1 General

1) All controls shall be electric over hydraulic.

2) All switches, valves, levers, controls, and adjustments used to start, stop, or operate the machine shall be clearly labeled with weather and wear resistant plates permanently affixed to the machine or component.

3) Controls used in continuous operation of the machine shall be within easy reach of the operator and shall not interfere with his/her view of the work.

4) Instruments and gauges not inside a closed, lockable cab, shall be protected from vandalism.

5) The engine shall not start with controls in travel position.

6) Gauges shall be the back lighted type. All switches and controls shall be easily interpreted at night.

5.6.2 Emergency Shutdown

1) A red emergency shutdown control shall be quickly accessible to the operator.

2) Each corner of the Unit shall have a red emergency shutdown control that is quickly accessible to work crew.

3) The shutdown control shall stop the engine, apply the Unit brakes, and illuminate.

5.6.3 Switches (minimum):

1) Windshield Wiper - Front

2) Windshield Wiper - Rear

3) Defroster Fan - Front

4) Defroster Fan - Rear

5) Headlights - Front/Rear – Headlights shall be selectable, but automatically change based on Unit travel direction

6) Interior Lights - On/Off

Cab and Controls – 5

7) Exterior Work Lights

8) Exterior Perimeter Lights

9) Key Switch, with accessory position

5.6.4 Gauges (minimum):

1) Oil Pressure Engine

2) Water Temperature

3) Volts

4) Fuel Level

5) Tachometer – RPM

6) Speedometer

7) Air Pressure (if applicable)

8) Hour Meter

5.6.5 Displays (minimum):

1) Diagnostic display Brand Name or Equal to Murphy PowerView® using J1939 engine interface protocol. A PLC display programed to accomplish this task is acceptable with WMATA approval.

5.6.6 Controls (minimum):

1) Throttle

2) Service Brakes

3) Forward / Reverse

4) Gear Select

5) Railroad Horn (overhead pull cable) – 96 decibels and the maximum volume level is 110 decibels

6) Low decibel Electric Horn (push button on operators console)

7) Parking Brake

8) Work Head Controls

20 V-1.2 – E-Clip Applicator – Technical Specification

5.6.7 Indicators

1) Low Air Pressure (if applicable)

2) Hydraulic Controls Active

3) Parking Brake Engaged

5.7 CAB WATER LEAKAGE TEST

1) The Contractor shall perform a test to assure there is no leakage of water into the cab as may occur during operation in the ambient conditions described in Section 2.1.4 or as when the Unit is in a car washing facility.

5.8 TESTING REQUIREMENTS

Test Description

Section Reference

Qualification Test, at Contractor Location

Pre Shipment Test, at Contractor

Location Conformance Test, at WMATA Location

Acceptance Test, at WMATA Location

HVAC

Functional Test 5.4 X

Functional Test of All Controls 5.6 X

Water Leakage Test 5.7 X

Diagnostic System – 6

6 DIAGNOSTIC SYSTEM

6.1 DIAGNOSTICS

1) The Units shall include a diagnostic system with capabilities for analysis, maintenance and service for all circuits.

2) Diagnostic devices, such as test port connections or transducers, can be fixed or removable.

a) Removable devices must be designed with the ability to connect provided gauges and diagnostic equipment easily and quickly under full system pressure.

b) Diagnostic connections or transducers shall be clearly identified and easily accessible for ease of use under all operational conditions.

c) The contractor shall supply four (4) complete sets of field diagnostic equipment necessary to evaluate the overall functionality of the complete operation system of the equipment to include all OEM engine and transmission codes and remote monitoring stations (CDRL 06-01).

d) Field diagnostic equipment includes all applicable software and durable portable computers (hardbody laptops) necessary to evaluate all operating conditions and fault codes both in the field and shop environments.

e) Any portable diagnostic interface equipment must be contained for proper storage and transportability.

f) Instructions for use of all diagnostic equipment shall be included.

g) Any programmable devices or electronic controller shall have interface capability.

h) The original program copies and any subsequent updates, for the life of the machine (10 years), shall be provided along with any software or devices necessary to upload the program.

i) The diagnostic equipment listed above shall include the interface device, software and any connection hardware required.

j) Any/all devices shall be capable of reading/streaming all information and signals processed by the controller/programmable device.

3) Any diagnostic software subscriptions that require purchase from outside suppliers shall be included for 10 years or the life of the vehicle whichever is shorter.

6 – Diagnostic System

22 V-1.2 – E-Clip Applicator – Technical Specification

6.2 SIGNALS

1) The VMDS must record, at a minimum, FRA-mandated event recorder data (49 CFR 229.135 for event recorders) as applicable to the Unit. Additionally, vehicle specific data should be recorded including:

a) Service Brake Pressure

b) Parking Brake engaged

c) Engine rpm

d) Transmission Gear

e) All Operational Lockouts

f) Vehicle speed

g) All Shutdowns

6.3 SAMPLING AND STORAGE

1) The VMDS must record all signals at a 10 Hz or greater frequency. The VMDS should have sufficient memory to store 48 hours of data without overwriting.

6.4 DOWNLOAD

1) Data recorded on the VMDS must be available for download using a USB 2.0 or approved alternate communications connector. The data may be transferred to a portable test unit (PTU) application or directly to memory storage on the PTU. The VMDS data shall be recorded in a structured format compatible with standard spreadsheet software, such as MS Excel, so that statistical analysis may be conducted after download.

6.5 TESTING REQUIREMENTS

Test Description

Section Reference

Qualification Test, First Unit at

Contractor Location

Pre Shipment Test, All Units at

Contractor Location

Conformance Test, First Unit at WMATA

Location

Acceptance Test, All Units at WMATA

Location Diagnostic

System Test 6 X

6.6 DELIVERABLES

Diagnostic System – 6

06-01 6.1.2).c) List of diagnostics provided by diagnostic system Vehicle Delivery

7 – Electrical Equipment

24 V-1.2 – E-Clip Applicator – Technical Specification

7 ELECTRICAL EQUIPMENT

7.1 GENERAL

1) Battery charging alternator shall have a rated capacity to handle all equipment and accessories with a 30% reserve.

2) The DC Electrical System shall be 24 volts and shall use a PLC system for any logic functions. The PLC must be a proven design (such as Danfoss +1). All interface hardware, a copy of the programing software, and a PLC code shall be included.

3) Circuit breakers shall be utilized for overload protection as required. Fuses shall not be utilized without WMATA approval.

4) Housings containing heat producing elements shall be properly ventilated.

5) Batteries shall be wet cell type with capacity to meet the requirements of Section 11.5.

6) Batteries shall be threaded stud type.

7) The primary topology of the Electrical Equipment is to be determined by the Contractor and will be presented at Design Presentation (CDRL 07-01).

7.2 VEHICLE GROUNDING

1) All ground paths shall be through ground bus or cable, not through the vehicle structure.

7.3 CIRCUIT BREAKERS

1) Circuit breakers shall be located so as to be readily accessible.

2) Circuit breakers shall be clearly labeled with circuit identification.

7.4 CABINETS

1) Cabinets not located within the cab shall be of a weatherproof, steel construction.

2) Panels shall be readily removable and parts easily accessible.

3) Adequate lighting shall be provided in cabinets.

Electrical Equipment – 7

4) Pipes, tubing, or hoses other than electrical conduit shall not enter cabinets.

5) Nominal voltages used shall be plainly shown on outside of cabinet if other than 24VDC.

6) All parts and groups of parts shall be identified by function and clear, simple, exact reference to service diagram and parts list. Labeling must be indelibly machine printed and affixed to the Unit or part. Integral units, such as a circuit board, shall be considered as one part, if intended to be replaced as a unit.

Complete parts identification shall be shown where practicable, in order to minimize errors and time-consuming reference to drawings or lists.

7) A complete set of schematics and layout drawings shall be permanently affixed to the interior on a readily accessible cabinet within the cab. All prints must be printed on water, oil, and tear resistant material.

7.5 BATTERY BOX

1) The battery box shall be designed to accommodate a minimum of two (2) maintenance free 31 series lead acid batteries.

2) The battery box shall be constructed of 12 gauge or thicker, 304 or 316 stainless steel.

3) The battery box shall incorporate sufficient vents so as to provide proper ventilation.

4) Drain holes shall be incorporated.

5) A readily accessible, lockable, battery disconnect switch shall be provided. The location of the switch shall be WMATA approved, with a preference being in the cab. The switch shall have clearly indicated off and on positions. Lock feature must have capability for the installation of ¼” carabiner clip or pad lock.

7.6 DELIVERABLES

CDRL Reference Deliverable Timing 07-01 7.1.7) Electrical Load Study 15 Days prior to

8 – Propulsion and Hydraulic Equipment

26 V-1.2 – E-Clip Applicator – Technical Specification

8 PROPULSION AND HYDRAULIC EQUIPMENT

8.1 GENERAL

1) The Unit engine shall provide power for propulsion and hydraulic functions. A hydrostatic, pressure compensated drive pump and motor configuration coupled to drive sprockets shall be used for propulsion.

2) The unit shall be four wheel drive.

3) For towing purposes, a mechanism approved by WMATA shall be provided to permit easy disengagement of the drive system to preclude damage to any component. Large step-by-step metal etched placards of instruction shall be installed inside the cab as well as on the outside of the Unit for towing operations.

4) An automatic back up alarm, compliant with 49 CFR 214.511, shall be provided. Alternative solutions may be presented to WMATA for approval, such as a movement alarm or a change of direction alarm that is not interruptible.

5) All fluid reservoirs shall have remote drain valves/ports located on outboard frame rails and terminated with a JIC cap.

8.2 DIESEL ENGINE

1) The engine shall be diesel, with adequate horsepower, to accomplish tractive effort and equipment tasks. Propulsion and traction calculations for engine selection must be submitted to WMATA for approval (CDRL 08-01).

2) The engine shall be a proven design already employed in MOW units at

WMATA.

3) If a cold weather package is necessary to meet starting requirements for the ambient conditions listed in Section 2.1.4, it shall not utilize ether or other consumables.

4) At the time of delivery, the engine shall be new, and certified Tier 4 Final (CDRL 08-02).

5) The engine shall have the following features:

a) A dry type, two-stage air cleaner with centrifugal pre-cleaner.

b) A restriction indicator for the air cleaner.

Propulsion and Hydraulic Equipment – 8

c) Spin on primary and secondary fuel filters. Filters shall be readily available through common distributors and a variety of manufacturers. OEM part numbers as well as cross-referenced part numbers shall be supplied.

d) An easily accessible spin-on oil filter and a remote engine oil drain shall be provided. Filters shall be readily available through common distributors and a variety of manufacturers. OEM part numbers as well as cross-referenced part numbers shall be supplied.

6) The engine shall be equipped with an engine shut down with audible alarm for low oil pressure, low coolant, and high temperature conditions.

7) Engine model number and engine type shall be provided with the proposal submission.

8) The engine shall be equipped with a sufficiently oversized engine cooling system to meet WMATA’s operating and ambient conditions in Section 2.1.4.

Fin spacing shall consider the WMATA work environment and potential for blockage from dirt and debris.

9) The engine compartment shall have sufficiently sized removable panels to allow ease of access for regular maintenance and repair functions. The design of this enclosure shall be WMATA approved. All panels shall be insulated against weather, sound, and vibration.

10) An interface that allows the technician to interface with the engine, read diagnostic codes, and run OEM engine test shall be provided.

8.3 EXHAUST

1) Machines shall have the exhaust discharge at least 12" above the cab top or as Tunnel Restrictions apply. (See ”WMATA Rapid Transit Car Clearance Envelope” drawing in Appendix). The engine exhaust pipe shall discharge to one side. The muffler shall be mounted as close to the engine as possible.

2) The exhaust system shall be so located that it will cause no adverse temperature rise in any other part of the equipment and so that no heat or exhaust gas can reach the operator.

3) Stainless steel tubing shall be used for all exhaust piping. Not more than 36" of flexible metal exhaust pipe may be used, where necessary to reduce transmission of vibration. All exhaust piping shall be properly braced as required at all junctions, and at the interfaces between the manifold and muffler. Vibration dampeners may be used if necessary. The system shall provide for expansion, contraction, vibration, and stress produced by operation of the machine. The system shall comply with the requirement for Diesel

28 V-1.2 – E-Clip Applicator – Technical Specification

Engines Exhaust and Emission Test. (See SAE-y-24A, SAE-j-1003, and SAE-j-1243) as well as EPA Recommendations Regarding Air Pollution.

4) When utilizing exhaust tubing, the end shall be horizontal with bevel cut or a rain cap incorporated to eliminate moisture entry into the exhaust system.

5) The Unit shall be equipped with an interruptible/delayable regen function on any exhaust components.

6) Hydraulics shall not be located near the exhaust system.

8.4 DIESEL EXHAUST FLUID TANK

1) Preference will be given to proposals with engines not requiring diesel exhaust fluid (DEF).

2) If DEF is used, the reservoir shall be mounted in close proximity to the diesel filler neck and such that the filler is readily accessible.

3) The reservoir shall be clearly labeled and have a blue DEF cap.

4) Capacity of the DEF tank shall be such that it will not require refilling more frequently than the fuel tank (CDRL 08-03).

8.5 AIR COMPRESSOR SYSTEM

1) If an air compressor is provided, it shall include the following:

a) Capacity to provide the required air for a typical work cycle without exceeding the supplier’s recommended duty cycle.

b) A governor to regulate output pressure.

c) A pressure relief valve.

d) An air dryer, Turbo 2000 or approved equivalent, with a heater element to prevent freezing.

e) Reservoir(s) sized to provide a minimum of three (3) full brake applications, if so configured.

f) Air system shall be configured in such a way that use of air components shall not deplete the reservoir for braking system.

g) Reservoirs shall conform to the ASME Pressure Vessel Code and stamped with ASME certification. Reservoirs shall have telltale holes.

h) Reservoirs must be standard truck type reservoirs conforming to SAE J10- B specifications. Certification shall be supplied to WMATA (CDRL 08-04).

i) All pipes and fittings shall be arranged to assure moisture drainage into reservoirs installed at the lowest points in the system.

j) Auto drain valve shall be included. The drain valve must not use fluctuations in tank pressure for triggering (such as DV2 type).

k) Reservoir shall have manual drain valves that can be left open.

8.6 FUEL TANK

1) Capacity of the fuel tank shall provide for continuous operation of the machine for a period of no less than 12 hours of operation at 50% of the rated output

(CDRL 08-05).

2) Filler opening shall have a minimum diameter of 1-1/2", a removable strainer (removable only with the use of common hand tools), and a hinged or chained vented filler cap.

3) A tank vent, other than the fill cap, shall be installed and located above the filler neck.

4) Tanks must be able to be filled without the potential of 3rd rail interference.

5) The filler opening shall be located so as to make it impossible for a fuel can or nozzle to contact electrically energized parts. Tanks shall be located to eliminate fire hazard from spill, overflow, or drainage of fuel.

6) The tank shall be configured such that leakage from the fuel filler and vents is prevented when Unit is on the maximum cross level of the system (Refer to Section 2.1.3).

7) The tank shall be located on the Unit, in a position that will provide protection against rupture in the event of collision or derailment.

8) The tank shall incorporate a top loading port, a sight gauge for fuel levels, a remote fuel gauge (cab console); and a 3/4" drain valve with a pipe plug and provisions for a padlock.

9) Check valves and shutoff valves shall be used on all feed lines connected to the tank.

30 V-1.2 – E-Clip Applicator – Technical Specification

10) The tank shall have internal baffles, unless approved, to prevent sloshing of fuel during travel.

11) The tank shall comply with MFPA FCLCH 30 (Flammable and Combustible Liquids Code Handbook).

8.7 HYDRAULIC SYSTEM

8.7.1 General

1) The hydraulic system shall conform to the recommendation of the National Fluid Power Association (NFPA), American National Standards Institute (ANSI), and the International Standards Organization (ISO).

2) Upon completion of manufacture and before any operation, all parts of the system shall be cleaned and free from contaminants. Threads, holes, cuts, flares, and machining must be deburred and cleaned.

3) Fluid temperature in the reservoirs shall be compatible with the fluid and system components but in no case shall it exceed 180°F at the reservoir outlet(s) while operating in a 100°F ambient. The minimum fluid temperature after 5 minutes warm up or during operation shall be at least 60° with a 20°F ambient.

4) Where failure of the power plant or pump can immobilize components in a position which would prevent moving of the Unit, a battery operated emergency pump shall be provided in the circuit to allow normalization of all equipment components and to release failsafe brakes for movement of the Unit to a proper location. The pump operation shall be prominently displayed on Unit tow placard.

5) A tank isolation valve/valves shall be provided to stop flow from the reservoir in the event of a catastrophic failure. The valve shall be locked in the open position with a wire seal.

6) All hydraulic hoses shall be secured by stud and clamp method, unless WMATA approved. Floating clamps are acceptable for hose routing. Hose protective covers shall be used where applicable to prevent scuff and chaffing.

Nylon ties shall not be acceptable for securing hoses or controlling routing.

7) All hydraulically actuated components shall have safety locks painted in “red” color.

8) ISO 46 hydraulic fluid shall be used unless approved by WMATA.

9) The system shall have EMA test ports for troubleshooting. The locations of the test ports shall be submitted to WMATA for approval (CDRL 08-06).

8.7.2 Filtering

1) The hydraulic system shall incorporate pressure and return filtration. Pressure sensitive returns, such as case drain lines, may be routed directly to tank.

2) Filters shall be readily available through common distributors and a variety of manufacturers. OEM part numbers as well as cross-referenced part numbers shall be supplied.

3) All pressurized fluid shall pass through the pressure filter which shall have a B10 rating of 75 or higher.

4) Hydraulic fluid supply for the hydraulic pump suction ports shall pass through a strainer with a B120 rating of 75 or higher.

8.7.3 Reservoir

1) All reservoirs shall be designed and constructed to prevent entry of foreign matter, including water, and sized to protect the hydraulic system against excessive heat or thermal conditions. Reservoirs shall be sized to provide at least one minute of dwell time or a 60-gallon capacity, whichever is greater.

2) Baffles shall be provided to separate intake and return lines to facilitate the separation of air and foreign matter from the hydraulic fluid, separate the pump inlet from the settling portion of the tank, and shall direct flow toward tank walls for maximum heat dissipation.

3) Access panels large enough for complete cleaning, inspection, maintenance, and servicing of filters shall be provided, with an accessible means to empty the reservoir in the event the fluid is to be retained.

4) An air inlet breather shall be provided which is of sufficient capacity to maintain approximately atmospheric pressure at maximum demands on the hydraulic system and to assure vacuum at suction lines shall not exceed manufacturer’s requirements in any operational situation. The air breather system shall be equipped with a 10 micron or finer filter, either cartridge or spin-on type.

5) All reservoirs shall incorporate magnets designed to capture metallic debris.

6) A fluid level gauge and thermometer in plain view and protected from damage shall be provided.

8.7.4 Oil Cooler.

32 V-1.2 – E-Clip Applicator – Technical Specification

1) An oil cooler shall be utilized to control the fluid temperature (Refer to Section 8.7.1).

2) A thermostatically controlled bypass shall be used. Alternative arrangements shall require WMATA approval.

3) The engine shall be equipped with an oversized oil cooler to meet WMATA’s operating and ambient conditions in Section 2.1.4. Fin spacing shall consider the WMATA work environment and potential for blockage from dirt and debris.

4) The oil cooler fan may be either…