ATTACHMENT_C_-_5_Ton_and_10_Ton_Swing_Loaders_-_Technical_Specifications.pdf

Version Record i

Car Track Equipment Maintenance (CTEM)

Technical Specifications – 5 and 10 ton swing loaders – Version-1.0 – 10/25/2018

Technical Specifications

5 and 10 ton swing loaders

Version Record ii V-1.0 – 5 and 10 ton swing loaders – Technical Specifications

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Table of Contents iii

Section/Sub-section Title Page

1. SCOPE

2. SYSTEM DESIGN

2.1 SYSTEM BASIS AND PARAMETERS

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 EQUIPMENT

3.4. DELIVERABLES

4. UNDERCARRIAGE

4.1. GENERAL

4.2. RIDE QUALITY

4.3. HI-RAIL SYSTEM

4.4. WHEELS, TIRES, AND AXLES

4.5. SUSPENSION

4.6. STEERING

4.7. TESTING REQUIREMENTS

4.8. DELIVERABLES

5. CAB AND CONTROLS

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

9.2. BRAKE EQUIPMENT

9.3. BRAKE REQUIREMENTS

9.4. TESTING REQUIREMENTS

10. COMMUNICATIONS

10.1. RADIO

10.2. CAMERA

10.3. TESTING REQUIREMENTS

v

11. LIGHTING SYSTEM

11.1. EXTERIOR LIGHTING

11.2. INTERIOR LIGHTING

11.3. WORK LIGHTING

11.4. EMERGENCY LIGHTING

11.5. TESTING REQUIREMENTS

11.6. DELIVERABLES

12. WORK HEAD

12.1. GENERAL

12.2. VISIBILITY

12.3. CONTROLS

12.4. WORK HEAD LOCKS

12.5. 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

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. AS BUILT DRAWINGS

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

NOTE: ALL DRAWINGS ARE APPLICABLE TO SWING LOADERS EVEN IF IT IS NOT

SPECIFICALLY INDICATED ON THE DRAWING ITSELF

System Design – 2

1. SCOPE

1.1. GENERAL REQUIREMENTS

1) These Specifications set forth the requirements for the, design, manufacturing, assembly, testing, delivery, performance and acceptance of both 5 and 10 ton swing loaders (hereunder referred to as the , “5 Ton Unit”, “10 Ton Unit”, or collectively referred to as the “Units,” “Equipment”, and “Machines”). In addition, this Specification includes requirements for program management, compliance demonstration, product support, and data submittals.

2) These Specifications are generally complete,, but it is not intended to describe all work details to be performed. This is a performance- based SOW, in which WMATA is giving the Contractor the freedom to determine how to meet WMATA’s requirements for technical acceptability..Therefore, the Contractor's solution will be influenced by its experience in building rail work equipment, on its examination of the Washington Metropolitan Area Transit Authority (WMATA) system, and on its detailed design, manufacturing and testing capabilities.

3) Training of WMATA’s staff in the operation and maintenance of the Units 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) Upon completion of manufacturing 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 technically acceptable.

6) References to commercial and industrial standards, specifications, and recommendations, whether stated or not stated as the latest revision, pertain to

2 – System Design the version in effect at the time of the proposal, unless specifically indicated otherwise.

7) 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.

8) 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 thise Specifications, 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.

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

1.2 WORK TO BE DONE

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

2) The Units, as herein specified, shall be delivered to a location on WMATA property as designated by Section 16.5.

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 Units shall be selected to obtain the maximum strength and reliability balanced against minimizing weight consistent with the Specifications. All parts shall be of a sufficiently robust design and

System Design – 2 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 Units shall be free from defects such as incomplete welds, welds that cross welds, corrosion, loose 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 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 Units, 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 coordinationwith 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 and diagnostics.

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

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

2 – System Design

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 Units. 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 Units shall be designed to have a minimum service life of ten (10) years, unless otherwise specified. The achievement of design life assumes compliance with WMATA maintenance intervals, with subsequent WMATA approved modifications arising from any Contractor recommendations 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 Units shall be equipped, at a minimum, with an approved power plant, brake equipment, hi-rail system, Heating, Ventilation, and Air Conditioning (HVAC) System, communications system, work head, and such other equipment as specified herein.

4) The Units shall be capable of operating under all exterior ambient conditions as specified in Section 2.1.4. Heat generated by 5 and 10 ton swing loaders equipment shall be taken into consideration in the design.

2.1.2 ARRANGEMENT

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

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

2) Each Unit shall be equipped with a forward mounted boom capable of lifting an180-degree rotation (swing). The work head shall be equipped with a WMATA approved quick interchange adapter compatible with a multitude of attachments.

3) Each Unit shall come equipped with a rigid boom, extended boom, and stiff hook.

Each Unit shall be equipped with controls for propulsion, hi-rail, and braking.

2.1 System Basis and Parameters – 0

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

5) Each Unit shall be equipped with an integral, hydraulically operated, hi-rail system (Refer to Section 4.3).

2.1.3 Operating Physical Environment

1) The Units 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 on rail 5% Maximum grade off rail 6%

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.

0 – 2.1 System Basis and Parameters

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) While on rubber tires, the Units shall be able to negotiate over rail and ballast without losing traction or becoming bogged in the ballast. The Units are not intended to operate on public roads.

2.1.4 Exterior Ambient Conditions

1) The Units 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 of WMATA’s 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

17.1.3 and 17.1.4.

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

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

a) “Crane Car Design Loading” (Reference 17.1.1)

b) ”WMATA Rapid Transit Car Clearance Envelope” (Reference 17.1.3)

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

(Reference 17.1.4)

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. This includes wheels, in hi-rail mode. Travel must be inhibited unless the wheels are oriented properly.A Steering wheel lock must also be incorporated to prevent steering wheel movement while in hi-rail mode.

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 and 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.. 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 Units shall be capable of travelling up a 5% grade on rail, and 6% grade off rail, while fully loaded. Minimum speed when traveling up a maximum grade shall be 10 mph under dry or wet conditions.

2) The Units shall be driven and 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 Units shall be capable of operating at a maximum speed of 25 mph without instability or oscillation on and off rail.

4) The Units shall have three (3) selectable travel gears with two (2) ranges (high and low).

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 on rail.

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) All Noise sources (including the machine cab shall l comply with 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) Refer to Appendix “Crane Car Design Loading” (Reference 17.1.1) drawing for the basic 5 and 10 ton swing loaders vehicle weight.

2) Equipment shall be distributed along the Unit such that the load on each axle falls within the range of 25%±5% of the total dead load. While loaded, the balance shall be dictated by the Unit lifting charts.

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 Units 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, 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 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).

2.9. 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 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

– 0

3. CONSTRUCTION AND ASSEMBLY

3.1. GENERAL

3.1.1 Lifting Points

1) Each 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) Each 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 only).

a) Tow eyes must be perpendicular to top of rail in the hi-rail position.

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 at a minimum, 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 130,000 lbs. Refer to Appendix 17.1.5 (for reference only).

3.2. STRUCTURAL REQUIREMENTS

1) As a method of demonstrating that the structure is fit for its intended purposes, 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).

3 – Construction and Assembly

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 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) Underframe equipment shall be equipped with safety straps in order to meet the requirement.

3) Driveshafts shall have safety loops.

3.4. DELIVERABLES

03-01 3.2.1) Documentation of Service Proven Design or

Stress Analysis Results 15 Days prior to

4. UNDERCARRIAGE

4.1. GENERAL

1) The undercarriage shall be of a service proven design that meets the requirements stated 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. HI-RAIL SYSTEM

1) Units shall be equipped with a hydraulically deployable hi-rail system that allows the Unit to be used on-rail within WMATA’s system.

a) The hydraulic system shall apply constant regulated pressure to the rail gear to maintain proper friction with the drive hub and tire contact with the use of hydraulic locking devices such as counter balance valves or pilot operated check valves. Mechanical locks are prohibited.

b) This system shall include an alarm to alert the operator, if the friction drive hub is not in proper contact with the tire to develop adequate traction or braking.

c) The system shall accommodate tire wear throughout their life cycle without adjustment.

2) The hi-rail equipment shall be driven by rubber tires riding on drums.

a) The drive hubs shall be straight lobed or helix lobed cast steel drum that is designed not to prematurely wear or cut the tire.

4 – Undercarriage

3) The Units shall be capable of being off-tracked and on-tracked by its own means.

4) Hi-Rail shall have a positive lock for on-rail and off-rail travel modes.

5) The Units shall be equipped with wheel guards (fenders).

6) The Units shall be equipped with shunting devices.

4.4. WHEELS, TIRES, AND AXLES

4.4.1. Rail Wheels

1) Unit to be fitted with four (4) hi-rail wheels.

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

3) Diagonal measurements shall be within tolerance of American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering Chapter 27 Section 2.1.4.e.

4) Rail wheels shall be 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 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.

5) Rail wheel diameter shall be minimum sixteen (16) inches.

6) Wheel profile shall be AAR 1B wide,.

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

8) 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).

9) The Unit’s 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.

Undercarriage – 4

4.4.2. Tires

1) The Units shall have four (4) G3, high ply, non-directional, self-cleaning tires with a rock or rock-flush tread pattern and heavy duty side walls of not less than 40 inches in overall diameter.

2) All tires shall be virgin foam filled.

4.4.3. Axles

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

2) Axles shall be heavy duty and ribbed.

3) The Units shall have (positive) four-wheel drive (on and off rail).

4.5. SUSPENSION

1) Rear axle shall oscillate freely in off-rail mode. Automatic travel stops shall limit oscillation for on-rail and side lifting use.

4.6. STEERING

1) Units shall have hydrostatic power steering systems controlled using a rotary (orbitrol) valve.

2) The Units shall be capable of four (4) steering modes and controlled from the cab:

a) Front steering only,

b) Rear steering only,

c) Front and rear radius steering, and

d) Crab steering.

3) The rear steering shall have a positive lock when in front steering mode. The front shall have a positive lock when rear steering mode is enabled.

4 – Undercarriage

4) The Units shall be capable of achieving a minimum turning radius of 21 ft. on flat ground while on tires.

4.7. 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 Stable Ride

Quality at Max Speed

4.2.1) X

Functional Demonstration of Hi-Rail System

4.3 X

Wheel-to-wheel Impedance 4.4.1.9) X

4.8. DELIVERABLES

04-01 4.4.1.7) Axle Assembly Drawings 5 Days prior to Production 04-02 4.4.1.8) Axle Press Records 5 Days after Production Begins

0 –

5. CAB AND CONTROLS

5.1. GENERAL

1) A cab containing all appurtenances necessary for the operation of the Unit shall be included.

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 of door locks.

4) The cab shall tilt to allow maintenance personnel access to system components and shall contain a positive locking safety component.

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

5.2. ARRANGEMENT

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

5.3. CAB WINDOWS

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

2) The windshield wipers shall clear at least 75 % of the front and rear facing 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 – Cab and Controls

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 68° F or greater

1) The cooling system shall be sized to maintain an interior temperature of 78° F or greater.

2) Front and rear facing windows shall be equipped, , with defrosting fans to ensure at least 80 percent of the viewing area is free of frost and fog. Optional forced air defrost mechanism may be proposed for approval.

5.5. CAB EQUIPMENT

5.5.1. Seats and Visibility

1) A seat interlock device shall be supplied to prevent operation of the hydraulics system without an operator properly positioned.

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

3) 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.

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

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

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

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

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

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) The DVR shall incorporate security features so 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.

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 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 theft or vandalism.

5) The engine shall not start with controls in the 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) The shutdown control shall stop the engine, apply the Unit brakes, and the cabin itself shall 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;

7) Exterior Work Lights - Front/Rear;

8) Key Switch, with accessory position.

5.6.4. Gauges :

1) Oil Pressure Engine;

2) Water Temperature;

3) Volts;

4) Fuel Level;

5) Tachometer – RPM;

6) Speedometer;

7) Air Pressure;

8) Transmission Pressure;

9) Transmission Temperature;

10) Hour Meter;

5.6.5. Displays :

1) Diagnostic display using an SAE J1039 engine interface protocol. A PLC programmed display is acceptable. An example of an acceptable diagnostic display is the Murphy PowerVIew.”

5.6.6. Controls :

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) Low / High speed selection controls;

9) Boom Controls;

10) Hi-Rail Up / Down;

11) Steering Mode.

5.6.7. Indicators

1) Steering straight;

2) Hi-Rail engaged;

3) Axle Locked;

4) Low Air Pressure;

5) Hydraulic Controls Active;

6) 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, 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

HVAC

Functional Test 5.4 X

Functional Test of All Controls 5.6 X

Water Leakage Test 5.7 X

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, shall be supplied.

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 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 operations system of theUnits. The Contractor shall include all OEM engine and transmission codes and remote monitoring stations (CDRL 06- 01).

d) Field diagnostic equipment includes all applicable software licenses and durable portable computers (hardbody laptops) necessary to evaluate all operating conditions and fault codes both in the field and shop environments. WMATA must approve all end user license agreement, terms of service or other ancillary agreements such as master service agreements.

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 capability.

6 – Diagnostic System

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 WMATA to purchase a license from outside suppliers shall be included for ten

(10) years or the life of the vehicle whichever is shorter. WMATA must review and the parties must agree upon any ancillary agreements such as end user software license agreements, Terms of Service, and/or Master Service Agreements.

6.2. SIGNALS

1) The VMDS must record, at a minimum, Federal Railroad Administration (FRA) mandated event recorder data (See 49 C.F.R.§ 229.135 for event recorder requirements) as applicable to the Unit. Additionally, vehicle specific data must be recorded including:

a) Service Brake Pressure;

b) Parking Brake Status;

c) Engine rpm;

d) Transmission Gears;

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.

Diagnostic System – 6

6.4. DOWNLOAD

1) Data recorded on the VMDS must be available for downloading using a USB 2.0.. 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

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

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 12 or 24 volts and shall use a PLC system for any logic functions. The PLC must be a proven design (an acceptable example is Danfoss +1). All interface hardware, a copy of the programing software, an agreed upon software license, and PLC code shall be included.

3) Circuit breakers shall be utilized for overload protection as required.

Fuses shall not be utilized..

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 11.4.

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’s structure.

7.3. CIRCUIT BREAKERS

1) Circuit breakers shall 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 constructed with weatherproof steel.

Electrical Equipment – 7

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

3) Adequate lighting shall be provided in cabinets. .

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

5) Nominal voltages used shall be plainly shown on the outside of the cabinet ,if other than 12 or 24 volts DC.

6) All parts and groups of parts shall be identified by function with a clear, simple, and exact reference to a service diagram. A comprehenseive parts list shall be included. Labeling must be indelibly machine printed and affixed to the Unit or part. Integral units, such as a circuit boards, and their parts shall be considered as one part, if intended to be replaced as a unit. Complete parts identification shall be shown , in order to minimize errors and time-consuming references to drawings or lists.

7) A complete set of schematics and layout drawings shall be permanently affixed to the interior of 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 be vented according to the battery manufacturer guidelines for the quantity, size and ratings.

4) Drain holes shall be incorporated.

5) A readily accessible, lockable, battery disconnect switch shall be provided. The location of this switch shall be in the cab. The switch

7 – Electrical Equipment 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

07-01 7.1.7) Electrical Load Study 15 Days prior to

8. PROPULSION AND HYDRAULIC EQUIPMENT

8.1. GENERAL

1) The Unit’s engine shall provide power for propulsion and hydraulic functions. A power-shift automatic transmission, with oil cooler, coupled to gear driven axles shall be used for propulsion.

2) For towing purposes, a mechanism shall be provided to permit easy disengagement of the drive system to preclude damage to any component. Large, step-by-step metal etched f instruction placards shall be installed both inside and outside the cab for towing operations.

3) The transmission shall be equipped with a reverser that enables the unit to attain full travel speed in either direction.

4) An automatic back up alarm, compliant with 49 C.F.R.§ 214.511, shall be provided.

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 meet and accomplish tractive effort and equipment tasks. Propulsion and traction calculations for engine selection shall be submitted to WMATA for approval (CDRL 08-01).

2) The engine shall be a proven design already employed in Maintenance of Way (MOW) units.

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.

8 – Propulsion and Hydraulic Equipment

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 a centrifugal pre-cleaner and a restriction indicator.

b) 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.

c) 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 tilt open or 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 tests shall be provided. Any software license necessary shall be provided for the expected life of the machine. The terms and conditions of all end user software licenses, Terms of Service, Master Service agreement, or any other ancillary agreement shall be reviewed and approved by WMATA.

Propulsion and Hydraulic Equipment – 8

8.3. EXHAUST

1) The exhaust system shall be located so 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.

2) Stainless steel tubing shall be used for all exhaust piping. Not more than 36" of flexible metal exhaust pipe may be used, where it is necessary to reduce vibration. All exhaust piping shall be properly braced 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 Society of Automotive Engineers SAE-j-1243) as well as EPA recommendations regarding air pollution.

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

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

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

8.4. DIESEL EXHAUST FLUID TANK

1) Engines without a diesel exhaust fluid (DEF) requirement shall be considered first for the unit design. If achieving the performance requirements require an engine with DEF, it shall meet the requirements in this section.”

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:

Change to “Engines without a diesel exhaust fluid (DEF) requirement shall be considered first for the unit design. If achieving the performance requirements require an engine with DEF, it shall meet the requirements in this section.”

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, with a heater element to prevent freezing.

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

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

g) Reservoirs shall conform to the American Society of Mechanical Engineers (ASME) Pressure Vessel Code and stamped with ASME certification. Reservoirs shall have telltale holes.

h) Reservoirs must be standard truck type reservoirs conforming to Society of Automotive Engineers (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) 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 24 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 to make 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 fuel drainage.

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

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

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

8.7. HYDRAULIC SYSTEM

8.7.1. General

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

2) Upon completion of manufacturing 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 outlets while operating in an 100°F ambient temperature. The minimum fluid temperature after 5 minutes of warm up or during operatiosn shall be at least 60°F with a 20°F ambient temperature.

4) If failure of the power plant or pump could immobilize components in a position that would prevent moving the Unit, a battery operated emergency pump shall be provided 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 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 by stud and clamp method.. Floating clamps are acceptable for hose routing. Hose protective covers shall be used 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..

9) The system shall have EMA test ports for troubleshooting. The locations of the test ports shall be submitted to WMATA for approval post award (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 from excessive heat or cold. . 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 which will facilitate the separation of air and foreign matter from the hydraulic fluid, separate the pump inlet from the settling portion of the tank, and direct flow toward tank walls for maximum heat dissipation.

3) Spacious access panels to facilitate complete cleaning, inspection, maintenance, and servicing of any internal 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 spacious capacity to maintain approximate atmospheric pressure at maximum demands on the hydraulic system and to assure vacuum at suction lines shall not…