ATTACHMENT_B_-_Tie_Plate_Inserter_-_Technical_Specifications.pdf

WMATA

Vehicle Program Services (CENV)

Car Track Equipment Maintenance (CTEM) Technical Specifications – Tie Plate Inserter – Version-1.2 – 10/31/2018

FQ19110/WJ - Appendix A

Preventive Maintenance MaApApAnAual

Technical Specifications

Tie Plate Inserter

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Version Record

Technical Specifications – Tie Plate Inserter – V-1.2 i

Table of Contents

Technical Specifications – Tie Plate Inserter – V-1.2 iii

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

iv V-1.2 – Tie Plate Inserter – Technical Specifications

5.1 GENERAL

5.2 ARRANGEMENT

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

Technical Specifications – Tie Plate Inserter – V-1.2 v

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 WORK HEAD LUBRICATION

12.7 ACCESSORIES

12.8 TESTING REQUIREMENTS

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

vi V-1.2 – Tie Plate Inserter – Technical Specifications

14.2 DESIGN REVIEWS

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

Technical Specifications – Tie Plate Inserter – V-1.2 1

1 SCOPE

1.1 GENERAL REQUIREMENTS

1) These Specifications set forth the requirements for the design, manufacturing, assembly, testing, delivery, performance and acceptance of Tie Plate Inserter (hereunder referred to as the “Unit”). These Specifications include 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 Washington Metropolitan Area Transit Authority’s (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 15.

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

5) 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.

6) 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 in compliance with requirements in Chapter 13 of the Technical Specifications.

7) 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.

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

• ASTM-A-325 Standard

• ISO 16889 Standard

1 – Scope

2 V-1.2 – Tie Plate Inserter – Technical Specifications

• 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

9) References to sections within this Specifications 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.

10) If at any time the Contractor finds that any requirement of these Specifications appears to be in error or in conflict with these Specifications, then it shall immediately bring the apparent problem to COTR’s attention, in writing. WMATA will determine whether or not the Specification needs to be modified.

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

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. These Specifications set forth the performance requirements for the Unit.

2) The Unit, as herein specified, shall be delivered to a location on WMATA property as designated by Section 15.4.

3) The Contractor shall submit documentation (drawings, analyses, calculations, etc.) with detailed technical information according to the Contract Data Requirements List (CDRL’s) in order to demonstrate specification compliance. WMATA's review, comments, or approval will not relieve the Contractor of its sole responsibility for the Unit's design. The

Scope – 1

Technical Specifications – Tie Plate Inserter – V-1.2 3

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 to Proceed date.

1.3 MATERIALS

1) Materials for the construction of the Unit shall be selected to obtain the maximum strength and reliability while minimizing the weight consistently with these Specifications. All parts shall be of a sufficiently robust design and implementation to survive the environment and operation described herein.

The components are 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, cross-welds, corrosion, loose or improper fasteners, any leaks or contamination, and any other defects that would impair or limit its operation or serviceability. All welds must comply with all of the American Welding Society’s (AWS) standards.

3) The Contractor shall accpect full responsibility for inspection and quality of material and workmanship (see Section 13). All materials and equipment furnished by the Contractor shall be new and shall be subject to inspection and approval by WMATA.

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 with 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.

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

1 – Scope

4 V-1.2 – Tie Plate Inserter – Technical Specifications

3) All non-proprietary software code shall be provided to WMATA. At minimum, all Programmable Logic Controller (PLC) logic trees shall be provided.

4) Software changes and updates shall be conducted by the Contractor during the Contract’s performance period, and continue for an additional maintenance period agreed to by the parties.

System Design – 2

Technical Specifications – Tie Plate Inserter – V-1.2 5

2 SYSTEM DESIGN

2.1 SYSTEM BASIS AND PARAMETERS

2.1.1 General

1) This section establishes the functions, system and 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 may impact system and subsystem design.

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

Meeting this requirement assumes compliance with WMATA’s required maintenance intervals, including any subsequent WMATA-approved modifications that may arise from any Contractor recommendations, and assumes the Unit is maintained and operated according to standard WMATA practices. The duty cycle of the Unit is defined as continuous operation for 12 hours, and up to 4,500 hours per year.

3) The Unit shall be equipped, at a minimum, with an approved power plant, braking system, Heating, Ventilation, and Air Conditioning (HVAC) System, communications 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 Tie Plate Inserter 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 tie plates.

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

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

2 – System Design

6 V-1.2 – Tie Plate Inserter – Technical Specifications

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

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 superelevation 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 occurs when 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 curves is determined by the formula L = (G1 - G2) 100 where L = Length in feet and (G1 - G2) = Algebraic difference in percentage grade. 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 under the anticipated climate conditions listed below:

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

Technical Specifications – Tie Plate Inserter – V-1.2 7

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 of WMATA’s tracks, tunnels, and structures while staying 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” diagrams in Appendix 16.1.3 and 16.1.4.

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

3) The Unit and its appurtenances shall successfully operate and negotiate within the constraints of WMATA’s System. The following drawings exhibit the guide way constraints (Reference Appendix):

a) “Crane Car Design Loading” (Reference 16.1.1)

b) “WMATA Rapid Transit Car Clearance Envelope” (Reference 16.1.3)

c) “METRO Rapid Transit Car – Dynamic Outline, Under Floor Car Clearance” (Reference 16.1.4)

4) Components that may encroach upon tracks, signals, crossings, 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.

6) All components that 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 in all locations where personnel may board the unit. The lowest step used for boarding the machine shall not

8 V-1.2 – Tie Plate Inserter – Technical Specifications 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, 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 m.p.h. under dry or wet conditions.

2) The Unit shall permit operation at maximum speed and fully loaded, 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 during 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) Noises shall be in 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.

Technical Specifications – Tie Plate Inserter – V-1.2 9

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/AVAILABLITY

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

2) Availablity of the unit is critical. The Unit shall not expirence more than two

(2) failures requiring corrective maintence between Preventative Maintenance and Inspection (PMI) Cycles.

2.7 MAINTENANCE

2.7.1 General

1) The Unit shall incorporate a design that allows easy access, for service, replacing parts, and adjusting them 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 Original Equipment Manufacturer (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 computerized Vehicle Monitoring and Diagnostic System (VMDS) for the Unit. 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 – Tie Plate Inserter – Technical Specifications

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

Technical Specifications – Tie Plate Inserter – V-1.2 11

3 CONSTRUCTION AND ASSEMBLY

3.1 GENERAL

3.1.1 Lifting Points

1) The Unit shall be capable of being lifted with a crane hook, without damage to the Unit or any of its equipment.

2) The lifting points and balance points must be clearly marked and labeled on the Unit.

3) The Unit shall come equipped with designated tie-down points, jack pads, and all rigging required for loading and unloading it on a flatbed truck. All equipment used for these purposes 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 16.1.5.

3.2 STRUCTURAL REQUIREMENTS

1) As a method of demonstrating that the unit is fit for its intended purposes, the Contractor shall meet the following requirements. (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.

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.

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

3 – Construction and Assembly

12 V-1.2 – Tie Plate Inserter – Technical Specifications

3) Warning lights and buzzers shall be utilized indicating when the turntable is in use.

3.4 UNDERFRAME EQUIPMENT

1) Underframe equipment shall be safety mounted such that failure of mounting hardware will not allow components to fall on 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

Technical Specifications – Tie Plate Inserter – V-1.2 13

4 UNDERCARRIAGE

4.1 GENERAL

1) The undercarriage shall consist of a service-proven design that meets the requirements herein. Exceptions shall be approved by WMATA.

4.2 RIDE QUALITY

No excessive vibration, wobble, or eccentric action shall occur at any speed for which the unit is intended. The Unit design shall provide for damage-free operation under maximum foreseeable operating stresses. The entire Unit 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) The Unit’s wheel gauge shall fit WMATA’s standard track gauge of 56-1/2 inches.

2) Diagonal Measurements shall be within tolerances specified by the American Railway Engineering and Maintenance-of-Way Association (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 Association of American Railroads (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 the heat treating 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) inches.

4 – Undercarriage

14 V-1.2 – Tie Plate Inserter – Technical Specifications

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).

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) inches minimum in 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 the 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 the inboard and outboard rail areas, so that in the event of derailment, the Unit will 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 drawings and dimensions.)

Undercarriage – 4

Technical Specifications – Tie Plate Inserter – V-1.2 15

4.5 TESTING REQUIREMENTS

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 4.3.2.4) X

4.6 DELIVERABLES

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 – Tie Plate Inserter – Technical Specifications

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 inside diameter (I.D.) hasp ring in addition to any other type door locks.

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

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 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

5) The system housing must be made of steel, stainless steel or aluminum and be designed and located for ease of service and maintenance. Side cab mounting is preferred.

6) The refrigerant gas used in the HVAC system must be R134a.

7) The HVAC system output temperature and blower speed must be adjustable.

Cab and Controls – 5

Technical Specifications – Tie Plate Inserter – V-1.2 17

8) All electrical power to the HVAC system must be suppled through dedicated circuit breakers.

9) Positive pressure must be maintained by the filtered blower system. Fresh air intakes must assure a minimum of three (3) changes of air volume per hour.

10) All intake air must be filtered to a Particle Size Efficiency (PSE)/ Minimum Efficiency Reporting Value (MERV) rating of 5 or greater.

11) The heating system must be sized to maintain an interior temperature of at least 68° F in the ambient condition mentioned in section 2.1.4.

12) The cooling system must be sized to maintain an interior temperature of at least 78° F in the ambient condition mentioned in section 2.1.4.

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

5.5 CAB EQUIPMENT

5.5.1 Seats and Visibility

1) Operator seats shall be constructed of durable, non-toxic materials.

2) The operator’s position shall consist of a cushioned seat and back, employing natural or man-made leather, over 3" low smoke foam cushion.

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

4) The operator’s 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.

18 V-1.2 – Tie Plate Inserter – Technical Specifications

a) DVR shall incorporate cybersecurity 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 and adjacent to the 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 the Operator, and an American National Standards Institute (ANSI) Class A first-aid kit.

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 Unit shall be clearly labeled with weather and wear resistant plates permanently affixed to the Unit or a component thereof.

3) Controls used in continuous operation of the Unit 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 a 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 switch shall be quickly accessible to the operator.

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

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

Cab and Controls – 5

Technical Specifications – Tie Plate Inserter – V-1.2 19

5.6.3 Switches:

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;

7) Exterior Working 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) The Contractor shall provide Diagnostic displays / PLC display Brand Name or Equal to Murphy PowerView® using J1939 with engine interface protocol.

2) Controls:

20 V-1.2 – Tie Plate Inserter – Technical Specifications

1) Throttle;

2) Service Brakes;

3) Forward / Reverse;

4) Gear Select;

5) Railroad Horn (overhead pull cable) – at least 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.

5.6.6 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 thatmay occur during operation in the ambient conditions described in Section 2.1.4 or as when the Unit is in a 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 5.5 X

Water Leakage Test 5.6 X

Diagnostic System – 6

Technical Specifications – Tie Plate Inserter – V-1.2 21

6 DIAGNOSTIC SYSTEM

6.1 DIAGNOSTICS

1) The Unit 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 to quickly and easily connect gauges and diagnostic equipment under full system pressure.

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

c) The Contractor shall supply five (5) complete sets of field diagnostic equipment necessary to evaluate the overall functionality of the complete operational system of all 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 devices (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 controllers shall have interface capabilities.

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

6 – Diagnostic System

22 V-1.2 – Tie Plate Inserter – Technical Specifications

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

6.2 SIGNALS

1) The VMDS must record, the Federal Railroad Administration’s (FRA) mandated event recorder data (49 C.F.R.§ 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 Status;

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 must 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.

Diagnostic System – 6

Technical Specifications – Tie Plate Inserter – V-1.2 23

6.5 TESTING REQUIREMENTS

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

06-01 6.1.2).c) Diagnostic Equipment Vehicle Delivery

7 – Electrical Equipment

24 V-1.2 – Tie Plate Inserter – Technical Specifications

7 ELECTRICAL EQUIPMENT

7.1 GENERAL

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

2) The direct current (DC) Electrical System shall be 24 volts and shall use a PLC system for any logic functions. The PLC must be a proven design Brand Name or Equal to Danfoss +1. All interface hardware, a copy of the programing software, and 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 10.5.

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.

Electrical Equipment – 7

Technical Specifications – Tie Plate Inserter – V-1.2 25

3) Adequate lighting shall be provided in cabinets. Exceptions shall be approved by WMATA.

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 24 volts DC.

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 padlock.

7.6 DELIVERABLES

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

7 – Electrical Equipment

26 V-1.2 – Tie Plate Inserter – Technical Specifications

Propulsion and Hydraulic Equipment – 8

Technical Specifications – Tie Plate Inserter – V-1.2 27

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.

8 – Propulsion and Hydraulic Equipment

28 V-1.2 – Tie Plate Inserter – Technical Specifications

b) A restriction indicator for the air cleaner.

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

Technical Specifications – Tie Plate Inserter – V-1.2 29 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 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.

30 V-1.2 – Tie Plate Inserter – Technical Specifications

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 American Society of Mechanical Engineers (ASME) Pressure Vessel Code and shall be stamped with ASME’s certification. Reservoirs shall have telltale holes.

h) Reservoirs must be standard truck-type reservoirs conforming to the Society of Automotive Engineers specifications.(See (SAE) J10-B.)

Certification shall be supplied to WMATA at the time designated in CDRL 08-04.

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

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

k) Reservoirs 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 placed in a location that makes it impossible for a fuel can or nozzle to contact electrically energized parts. Tanks shall be located to eliminate fire hazards from spills, overflow, or drainage of fuel.

6) The tank shall be configured to prevent leakage from the fuel filler and vents when the 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.

Technical Specifications – Tie Plate Inserter – V-1.2 31

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 padlock provisions.

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

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

11) The tank shall comply with the National Fire Protection Association’s (NFPA) standard FCLCH 30 (Flammable and Combustible Liquids Code Handbook).

8.7 HYDRAULIC SYSTEM

8.7.1 General

1) The hydraulic system shall conform to the standards 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 temperature. The minimum fluid temperature after 5 minutes of warm up or during operation shall be at least 60° with a 20°F ambient temperature.

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

5) Tank isolation valve/valves shall be provided to stop the 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 using the stud and clamp method, unless WMATA approves an alternate during contract perfomance. Floating clamps are acceptable for hose routing. Hose protective covers shall be

32 V-1.2 – Tie Plate Inserter – Technical Specifications used where applicable to prevent scuffing 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 an alternate is approved by WMATA during contract performance.

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

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,and to separate the pump inlet from the settling portion of the…