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TECHNICAL SPECIFICATIONS

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					    TECHNICAL SPECIFICATIONS
                  For

DETROIT TRANSPORTATION CORPORATION

       DETROIT PEOPLE MOVER
     VEHICLE MID-LIFE OVERHAUL


            DTC IFB 4-002

            Issued for Bid:
            March 28, 2005




               Prepared by:
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS




                                         TABLE OF CONTENTS
SECTION 1           GENERAL ......................................................................................1-1
  1.1     Scope........................................................................................................1-1
  1.2     DPM Vehicle Description – Prior to Overhaul ...........................................1-2
  1.3     Basic Design Considerations ....................................................................1-4
  1.4     Standards..................................................................................................1-5
  1.5     Maintainability ...........................................................................................1-5
  1.6     Weights and Dimensions ..........................................................................1-6
  1.7     Definitions .................................................................................................1-7
  1.8     Disposition of Removed Materials.............................................................1-8
  1.9     Equipment Numbers .................................................................................1-8
  1.10    Manuals ....................................................................................................1-8
SECTION 2           INSPECTIONS, TESTS, QUALITY ASSURANCE .........................2-1
  2.1     General .....................................................................................................2-1
  2.2     Qualifications Tests (First Vehicle only) ....................................................2-2
     2.2.1      Static Brake Test ...............................................................................2-2
     2.2.2      Truck Clearance Test.........................................................................2-2
     2.2.3      Lighting Intensity................................................................................2-2
     2.2.4      Paint Adhesion Test...........................................................................2-3
  2.3     First Article Inspections .............................................................................2-3
  2.4     Static Tests (All DPM vehicles) .................................................................2-3
     2.4.1      Water Tightness Test.........................................................................2-3
     2.4.2      Electrical Wiring Test .........................................................................2-4
     2.4.3      Train Line Test...................................................................................2-4
     2.4.4      HVAC Test.........................................................................................2-4
     2.4.5      Brake Tests........................................................................................2-5
     2.4.6      Weights..............................................................................................2-5
     2.4.7      Door System ......................................................................................2-5
     2.4.8      Communications System ...................................................................2-5
     2.4.9      DC/DC Converter...............................................................................2-6
     2.4.10     VOBC and ATC Systems...................................................................2-6


Issue Date: 3/28/05                                     i
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


  2.5     Quality Assurance.....................................................................................2-6
     2.5.1      Quality Assurance Program ...............................................................2-7
     2.5.2      Quality Assurance/Quality Control .....................................................2-7
     2.5.3      Quality Assurance Plan......................................................................2-7
     2.5.4      Subcontractor Control ........................................................................2-8
     2.5.5      Configuration Control .........................................................................2-8
     2.5.6      Material Review Board.......................................................................2-8
     2.5.7      Metrology ...........................................................................................2-8
     2.5.8      Manufacturing/Production ..................................................................2-9
     2.5.9      Special Processes .............................................................................2-9
     2.5.10     Purchased Materials ........................................................................2-10
     2.5.11     Inspection Plan ................................................................................2-10
  2.6     DTC Participation....................................................................................2-11
  2.7     Shipment and Acceptance ......................................................................2-12
     2.7.1      Receiving Inspection at Contractor Facilities ...................................2-12
     2.7.2      Certificate of Inspection and Release for Shipment .........................2-13
     2.7.3      Receiving Inspection at DTC ...........................................................2-13
     2.7.4      Conditional Acceptance ...................................................................2-14
     2.7.5      Conditional Acceptance Tests .........................................................2-14
     2.7.6      Final Acceptance .............................................................................2-15
  2.8     Receipt of Contractor Furnished Materials..............................................2-15
  2.9     Storage of Materials................................................................................2-16
SECTION 3           MATERIALS AND WORKMANSHIP ..............................................3-1
  3.1     General .....................................................................................................3-1
  3.2     Standards..................................................................................................3-1
  3.3     Marking .....................................................................................................3-1
  3.4     Trim Finish ................................................................................................3-2
     3.4.1      Lumber...............................................................................................3-2
     3.4.2      Plywood .............................................................................................3-2
     3.4.3      Plymetal .............................................................................................3-2
     3.4.4      Asbestos ............................................................................................3-3




Issue Date: 3/28/05                                     ii
IFB 4-002 TECHNICAL SPECIFICATION                                                          TABLE OF CONTENTS


  3.5     Jointing and Fastenings ............................................................................3-3
     3.5.1      Fastenings .........................................................................................3-3
     3.5.2      HUCK Fasteners................................................................................3-4
     3.5.3      Torquing.............................................................................................3-4
     3.5.4      Plating................................................................................................3-4
     3.5.5      Cleaning.............................................................................................3-4
     3.5.6      Metal-to-Metal Fastenings .................................................................3-4
     3.5.7      Wood-to-Metal Fastenings.................................................................3-5
     3.5.8      Wood-to-Wood Fastenings ................................................................3-5
  3.6     Coating .....................................................................................................3-5
  3.7     Sealant......................................................................................................3-5
  3.8     Stainless Steel ..........................................................................................3-5
     3.8.1      Type...................................................................................................3-5
     3.8.2      Physical Properties ............................................................................3-5
     3.8.3      Gauge Tolerance ...............................................................................3-6
     3.8.4      Buffing and Polishing .........................................................................3-6
     3.8.5      Finish .................................................................................................3-6
  3.9     Low Alloy High Tensile Steel.....................................................................3-6
  3.10    Steel Castings...........................................................................................3-6
     3.10.1     Quality................................................................................................3-6
     3.10.2     Heat Treating .....................................................................................3-7
     3.10.3     Other Castings...................................................................................3-7
  3.11    Magnetic Particle Inspection .....................................................................3-7
  3.12    Radiographic Inspection ...........................................................................3-7
  3.13    Welding .....................................................................................................3-7
  3.14    Aluminum ..................................................................................................3-8
     3.14.1     Design Stresses.................................................................................3-8
     3.14.2     Fabrication and Fastening .................................................................3-8
     3.14.3     Protection of Contact Surface ............................................................3-8
  3.15    Fiberglass Reinforced Plastic....................................................................3-9
  3.16    Insulation.................................................................................................3-10
  3.17    Flammability, Smoke and Toxicity...........................................................3-10


Issue Date: 3/28/05                                    iii
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


  3.18    Elastomers ..............................................................................................3-10
  3.19    Metal Parts..............................................................................................3-10
  3.20    Substitute Materials ................................................................................3-10
  3.21    Truck Parts..............................................................................................3-10
  3.22    Glazing Materials - Glass ........................................................................3-11
  3.23    Hoses Piping & Tubing ...........................................................................3-11
     3.23.1     Hydraulic Brake Hoses, Piping and Fittings .....................................3-11
     3.23.2     Protection of Piping and Tubing.......................................................3-11
  3.24    Threaded Connections............................................................................3-12
  3.25    Wire and Cable .......................................................................................3-12
     3.25.1     Heater Connections .........................................................................3-12
     3.25.2     Headlight and Resistor Connections................................................3-12
     3.25.3     Aluminum Wire and Cable ...............................................................3-12
  3.26    Wiring & Connections .............................................................................3-12
     3.26.1     Application and Installation of Wire ..................................................3-12
     3.26.2     Solder ..............................................................................................3-13
     3.26.3     Tape.................................................................................................3-13
     3.26.4     Splices .............................................................................................3-13
     3.26.5     Terminals .........................................................................................3-13
     3.26.6     Terminal, Tool, and Die Manufacturer..............................................3-14
  3.27    Wire Marking...........................................................................................3-14
  3.28    Conduit ...................................................................................................3-14
  3.29    Electrical Devices and Hardware ............................................................3-16
     3.29.1     Contactors and Relays.....................................................................3-16
     3.29.2     Switches ..........................................................................................3-17
     3.29.3     Circuit Breakers ...............................................................................3-18
     3.29.4     Fuses ...............................................................................................3-19
     3.29.5     Bus Bars ..........................................................................................3-19
     3.29.6     Capacitors and Resistors.................................................................3-20
     3.29.7     Switch, Circuit Breaker, and Fuse Panels........................................3-20
     3.29.8     Illuminated Status Indicators and Annunciators ...............................3-21
     3.29.9     Rotating Equipment .........................................................................3-21


Issue Date: 3/28/05                                    iv
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


  3.30    Wiring......................................................................................................3-21
     3.30.1     Conductor Size ................................................................................3-22
     3.30.2     Wire Sizes and Types ......................................................................3-22
     3.30.3     Heater Connections .........................................................................3-22
     3.30.4     Headlight and Resistor Connections................................................3-22
     3.30.5     Aluminum Wire and Cable ...............................................................3-22
     3.30.6     Other Guidelines..............................................................................3-22
     3.30.7     Application and Installation of Wire ..................................................3-23
     3.30.8     Undercar and Overhead Wiring .......................................................3-23
  3.31    Electronics ..............................................................................................3-24
     3.31.1     Semiconductors ...............................................................................3-24
     3.31.2     Printed Circuit Boards ......................................................................3-26
  3.32    Software and Microprocessor Based Systems........................................3-27
     3.32.1     General ............................................................................................3-27
     3.32.2     Design Process................................................................................3-28
  3.33    Software Systems Functions and Features.............................................3-29
     3.33.1     Hardware Platform ...........................................................................3-29
     3.33.2     Operating Systems, Languages and Compilers...............................3-32
     3.33.3     General Features.............................................................................3-32
     3.33.4     Testability.........................................................................................3-33
  3.34    Software Documentation.........................................................................3-33
     3.34.1     Non-Commercially Available Software.............................................3-34
     3.34.2     User Documentation. .......................................................................3-35
     3.34.3     Commercially-Available Software ....................................................3-35
     3.34.4     Configuration Control .......................................................................3-36
     3.34.5     Software Maintenance and Related Tools .......................................3-36
     3.34.6     Test Equipment Software.................................................................3-36
  3.35    Welding ...................................................................................................3-36
     3.35.1     Responsibility...................................................................................3-36
     3.35.2     Welding Rod ....................................................................................3-37
     3.35.3     Heat Treating ...................................................................................3-37
     3.35.4     Welding Procedures ........................................................................3-37


Issue Date: 3/28/05                                     v
IFB 4-002 TECHNICAL SPECIFICATION                                                           TABLE OF CONTENTS


SECTION 4           STRUCTURAL AND FRAMING .....................................................4-1
  4.1     General .....................................................................................................4-1
  4.2     Underframe ...............................................................................................4-1
  4.3     Truck Attachments ....................................................................................4-2
  4.4     Underfloor Equipment Enclosures ............................................................4-2
  4.5     Outer Shell ................................................................................................4-2
  4.6     Collision Posts ..........................................................................................4-2
  4.7     End Caps ..................................................................................................4-3
  4.8     Insulation...................................................................................................4-3
  4.9     Side Trim Assemblies ...............................................................................4-3
  4.10    Side Windows ...........................................................................................4-3
  4.11    Hand Holds and Safety Bars.....................................................................4-3
  4.12    Floor Panels..............................................................................................4-4
  4.13    Side Door Threshold Plates ......................................................................4-4
SECTION 5           INTERIOR APPOINTMENTS.........................................................5-1
  5.1     General .....................................................................................................5-1
  5.2     Floor..........................................................................................................5-1
  5.3     Walls and Ceiling ......................................................................................5-2
     5.3.1      Window Masks and Side Liners.........................................................5-2
     5.3.2      Equipment Compartment and Bulkhead Panels ................................5-2
     5.3.3      Windscreens ......................................................................................5-2
     5.3.4      Ceiling Panels....................................................................................5-3
  5.4     Stanchions and Handrails .........................................................................5-3
  5.5     Seating......................................................................................................5-3
     5.5.1      Single and Double Seats ...................................................................5-3
     5.5.2      Pedestals ...........................................................................................5-3
     5.5.3      Seat Bases ........................................................................................5-3
     5.5.4      ADA Locations ...................................................................................5-4
SECTION 6           COUPLERS AND DRAFT GEAR ...................................................6-1
  6.1     General Scope ..........................................................................................6-1
  6.2     Couplers – Mechanical (Part No. 160137) ................................................6-1
  6.3     Couplers – Electrical, Right & Left (Part No. 160117) ...............................6-1


Issue Date: 3/28/05                                     vi
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


  6.4     Draft Gear (Part No. 160135)....................................................................6-2
  6.5     Coupler to Carbody Attachments ..............................................................6-2
  6.6     Mechanical and Remoter Electrical Uncoupling Features.........................6-2
  6.7     Coupler Centering Device (Part No. 160130)............................................6-2
  6.8     Uncoupling Device (Part No. 160143).......................................................6-2
  6.9     Operating Device (Part No. 160122).........................................................6-3
  6.10    Terminal Box Inspection (Part No. 152146) ..............................................6-3
  6.11    Front Face of Electric Coupler (Part No. 160128) .....................................6-3
  6.12    Other Components....................................................................................6-3
SECTION 7           DOORS ..........................................................................................7-1
  7.1     General Scope of Door System Overhaul .................................................7-1
  7.2     Side Doors ................................................................................................7-1
     7.2.1      Side Door Performance .....................................................................7-1
     7.2.2      Side Door Panels...............................................................................7-1
     7.2.3      Side Door Seals.................................................................................7-2
     7.2.4      Side Door Track and Operating Systems...........................................7-2
     7.2.5      Side Door Emergency Systems .........................................................7-3
  7.3     Emergency End Doors ..............................................................................7-3
  7.4     Emergency Stair Assembly .......................................................................7-4
  7.5     Sliding Pocket Door ..................................................................................7-4
  7.6     Equipment Locker Doors ..........................................................................7-4
  7.7     Door Control Systems...............................................................................7-4
     7.7.1      Door Control System Features ..........................................................7-4
     7.7.2      Door System Interfaces .....................................................................7-6
     7.7.3      Door System Failure Indications ........................................................7-7
SECTION 8           HVAC .............................................................................................8-1
  8.1     General Scope of HVAC Overhaul............................................................8-1
  8.2     Heating .....................................................................................................8-3
     8.2.1      Heating System Description...............................................................8-3
     8.2.2      Floor Heaters .....................................................................................8-3
     8.2.3      Overhead Heater ...............................................................................8-4




Issue Date: 3/28/05                                    vii
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


  8.3     Ventilation .................................................................................................8-4
     8.3.1      Ventilation System Description ..........................................................8-4
     8.3.2      Fresh Air Intake and Emergency Air Intake Ducts .............................8-5
     8.3.3      Ceiling Ducting and Diffuser Assembly ..............................................8-5
  8.4     Air Conditioning Unit .................................................................................8-5
     8.4.1      Air Conditioning System Description..................................................8-5
     8.4.2      Compressor .......................................................................................8-6
     8.4.3      Compressor/Condenser Fan Motor ...................................................8-6
     8.4.4      Motor Control Resistor Panel Assembly ............................................8-7
     8.4.5      Compressor/Compressor Motor Flexible Coupling ............................8-8
     8.4.6      Condenser Coil ..................................................................................8-8
     8.4.7      Liquid Receiver Tank and Refrigerant Lines ......................................8-8
     8.4.8      Filter Drier and Moisture Indicator......................................................8-8
     8.4.9      Evaporator Coil Assembly..................................................................8-8
     8.4.10     Compressor-Condenser Assembly Support Frame ...........................8-9
     8.4.11     Evaporator Blower Motor Assembly...................................................8-9
     8.4.12     System Evacuation and Charging....................................................8-10
  8.5     HVAC Controls........................................................................................8-10
     8.5.1      Refrigeration Controls Assembly .....................................................8-10
     8.5.2      HVAC Motor and Temperature Control Panel Assembly .................8-11
     8.5.3      HVAC Thermostats ..........................................................................8-11
     8.5.4      Control Modification .........................................................................8-12
SECTION 9           LIGHTING ......................................................................................9-1
  9.1     General .....................................................................................................9-1
  9.2     Interior Fluorescent Lighting......................................................................9-1
     9.2.1      Fixtures ..............................................................................................9-1
     9.2.2      Lighting Levels...................................................................................9-1
     9.2.3      Ballasts ..............................................................................................9-2
     9.2.4      Lamps ................................................................................................9-2
     9.2.5      Wiring.................................................................................................9-2
  9.3     Equipment Compartment Lighting.............................................................9-2
  9.4     Passageway Lighting ................................................................................9-2


Issue Date: 3/28/05                                   viii
IFB 4-002 TECHNICAL SPECIFICATION                                                          TABLE OF CONTENTS


  9.5     Headlights .................................................................................................9-2
  9.6     Marker Lights ............................................................................................9-3
  9.7     Indicator Lights..........................................................................................9-3
  9.8     Back Light Signs .......................................................................................9-4
  9.9     Testing ......................................................................................................9-4
SECTION 10          PROPULSION..............................................................................10-1
  10.1    General ...................................................................................................10-1
  10.2    Linear Induction Motors ..........................................................................10-1
     10.2.1     Windings ..........................................................................................10-1
     10.2.2     Laminated Core ...............................................................................10-2
     10.2.3     Structure and Mounting....................................................................10-2
     10.2.4     Cooling Fan Assemblies ..................................................................10-2
     10.2.5     Temperature Sensors ......................................................................10-2
     10.2.6     Power Connectors ...........................................................................10-2
     10.2.7     Scraper Blades, Clamp Bars and Skid Plates..................................10-3
  10.3    Power Conversion Units (PCU’s) ............................................................10-3
     10.3.1     Logic Control Bin .............................................................................10-3
     10.3.2     Inverter Pannier ...............................................................................10-3
     10.3.3     Auxiliary Power Supply (APS)..........................................................10-4
     10.3.4     Input Filter Reactors.........................................................................10-4
  10.4    DC/AC Inverters......................................................................................10-4
  10.5    Diode and Capacitor Panels ...................................................................10-4
  10.6    Testing ....................................................................................................10-4
     10.6.1     Continuity and Insulation Resistance ...............................................10-4
     10.6.2     Functional Testing ...........................................................................10-5
SECTION 11          POWER DISTRIBUTION .............................................................11-1
  11.1    General ...................................................................................................11-1
  11.2    Power Collectors.....................................................................................11-1
  11.3    Shop Power Switch.................................................................................11-1
  11.4    HV Fuse Panel (HVAC) ..........................................................................11-2
  11.5    DC/DC Converter....................................................................................11-2
  11.6    Battery ....................................................................................................11-2


Issue Date: 3/28/05                                     ix
IFB 4-002 TECHNICAL SPECIFICATION                                                          TABLE OF CONTENTS


  11.7     Battery Monitor and CB Panel.................................................................11-3
  11.8     LV CB Panel ...........................................................................................11-3
  11.9     LV Relay Panel .......................................................................................11-4
  11.10 Health Monitor.........................................................................................11-4
  11.11 DC/AC Inverters......................................................................................11-5
  11.12 HV Cables...............................................................................................11-5
  11.13 LV Wiring and Cables .............................................................................11-5
  11.14 Junction Boxes........................................................................................11-6
SECTION 12          BRAKE EQUIPMENT...................................................................12-1
  12.1     General ...................................................................................................12-1
  12.2     Friction Brake System .............................................................................12-1
     12.2.1      Caliper Assembly.............................................................................12-1
     12.2.2      Controls and Pump ..........................................................................12-2
     12.2.3      Hydraulic Piping and Hoses.............................................................12-2
     12.2.4      Rotors and Hubs..............................................................................12-2
  12.3     Track Brake Assemblies .........................................................................12-3
  12.4     Brake Interface Assemblies ....................................................................12-3
SECTION 13          TRUCKS ......................................................................................13-1
  13.1     General Scope ........................................................................................13-1
  13.2     Shipping and Receiving of DPM Vehicles ...............................................13-1
  13.3     Truck and Bolster Overhaul ....................................................................13-1
  13.4     Wheel and Axle Assembly ......................................................................13-2
SECTION 14          COMMUNICATIONS....................................................................14-1
  14.1     Communication System Description .......................................................14-1
  14.2     Scope of VCS Overhaul ..........................................................................14-1
  14.3     Passenger Access Panels ......................................................................14-2
  14.4     Hostlers Auxiliary Panels ........................................................................14-2
  14.5     Ceiling Mounted Public Address Speakers .............................................14-2
  14.6     Roof Mounted Antenna ...........................................................................14-2
  14.7     ADA Electronic Signs..............................................................................14-2
  14.8     VCS Testing............................................................................................14-3




Issue Date: 3/28/05                                     x
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


SECTION 15          VOBC ...........................................................................................15-1
  15.1    General Scope ........................................................................................15-1
  15.2    VOBC Equipment Locker ........................................................................15-1
  15.3    VOBC Equipment Cabling ......................................................................15-1
  15.4    Hostling Panel and Panel Electronics .....................................................15-1
  15.5    Antenna, Tachometers and Accelerometer.............................................15-2
  15.6    VOBC to Vehicle Interface Marshalling Panel.........................................15-2
  15.7    Software Upgrades .................................................................................15-2
  15.8    Documentation........................................................................................15-2
  15.9    Testing ....................................................................................................15-2
SECTION 16          PAINT AND GRAPHICS ..............................................................16-1
  16.1    General ...................................................................................................16-1
  16.2    Exterior ...................................................................................................16-1
  16.3    INTERIOR...............................................................................................16-1
  16.4    Underfloor ...............................................................................................16-1
  16.5    Equipment Enclosures ............................................................................16-2
  16.6    Trucks and Truck Mounted Equipment ...................................................16-2
  16.7    Decals and Signs ....................................................................................16-2
  16.8    Builder's Plate .........................................................................................16-3
SECTION 17          Miscellaneous ..............................................................................17-1
  17.1    Smoke Alarms.........................................................................................17-1
SECTION 18          TECHNICAL PUBLICATIONS AND TRAINING ...........................18-1
  18.1    General Scope ........................................................................................18-1
  18.2    Manual and Drawing Requirements and Format.....................................18-1
     18.2.1     General Publications Requirements ................................................18-1
     18.2.2     Manual Submittal and Review ........................................................18-2
     18.2.3     Printed Maintenance and Parts Manuals .........................................18-3
     18.2.4     Electronic Format.............................................................................18-3
     18.2.5     Technical Drawings .........................................................................18-4
     18.2.6     Conversion of Existing Microfiche Drawings to CD-ROM ................18-4
     18.2.7     Operating Instruction Books.............................................................18-5
     18.2.8     Maintenance Manuals......................................................................18-5


Issue Date: 3/28/05                                    xi
IFB 4-002 TECHNICAL SPECIFICATION                                                         TABLE OF CONTENTS


     18.2.9     Parts Manuals..................................................................................18-6
     18.2.10        Car History Books ........................................................................18-7
  18.3    Training ...................................................................................................18-7
     18.3.1     Training Class Requirements...........................................................18-8
     18.3.2     Training Materials and Presentations ..............................................18-8
     18.3.3     Evaluations and Certification ...........................................................18-9




Issue Date: 3/28/05                                    xii
IFB 4-002 TECHNICAL SPECIFICATION                                      1 - GENERAL


SECTION 1             GENERAL
1.1    SCOPE

The Detroit People Mover System is a 2.9-mile single-track elevated rail transit
system, arranged in a loop servicing the Detroit downtown area. The arrangement is
shown in Figure 1.1-1, System Layout. This specification describes the work that
shall be performed to overhaul and upgrade twelve (12) Detroit People Mover (DPM)
vehicles.


                          Figure 1.1-1, System Layout




Issue Date: 3/28/05                   1-1
IFB 4-002 TECHNICAL SPECIFICATION                                              1 - GENERAL


The Contractor shall be responsible for:
•     Removal of the DPM vehicles from the elevated system.
•     Transportation of the DPM vehicles from the DTC maintenance facility in Detroit,
      Michigan to the Contractor’s facility.
•     Overhaul and upgrade of the DPM vehicles in accordance with this technical
      specification including all materials and direct labor associated with this
      overhaul.
•     Delivery of overhauled DPM vehicles to the DTC maintenance facility in Detroit,
      Michigan. Delivery includes placement of the vehicles on the elevated rail
      system.
•     Testing of DPM vehicles in single and two car train consists during off service
      hours.
•     Resolution of any problems found as a result of tests and inspections.
•     Management, engineering, documentation and other tasks including:
            o   Design and engineering data.
            o   Spare parts.
            o   Manuals, catalogues, and car history books.
            o   Procedures and reports.
            o   In-service warranty support.
            o   Training.
            o   Quality assurance and control.

The Contractor shall submit material certifications for all new and replacement
materials indicating their compliance with the requirements of this technical
specification.

1.2     DPM VEHICLE DESCRIPTION – PRIOR TO OVERHAUL

The DPM vehicles were designed and build by UTDC between 1985 -1987. UTDC
was subsequently acquired by Lavalin and then by Bombardier in 1990. Larger fleets
of sister vehicles are currently in service in Vancouver (Sky Train – 150 vehicles)
and Toronto (Scarborough – 28 vehicles).
The cars have been in continuous service in Detroit since 1987. They have been
subject to monthly maintenance with progressively more intense work scopes.
The carbody is a modular design fabricated over an aluminum frame with aluminum
skin and molded fiberglass end caps. The exterior of the carbody including the
underframe is primed and painted. Exterior finish and markings are paint applied.
The carbody is in good condition. The general car arrangement is shown in Figure
1.2-1, Exterior Dimensions at the end of this Section. Pertinent dimensions are given
in Section 1.6.



Issue Date: 3/28/05                      1-2
IFB 4-002 TECHNICAL SPECIFICATION                                      1 - GENERAL




                                    Figure 1.2-1 Exterior Dimensions




Issue Date: 3/28/05           1-3
IFB 4-002 TECHNICAL SPECIFICATION                                        1 - GENERAL


The DPM vehicles are loaded from high platforms through quarter-point, bi-parting
doors on either side of the car.
The DPM vehicles are fully automated and are designed to operate at a maximum
safe speed of 50 mph (80 km/h). Although capable of operating as individual units,
DPM vehicles are operated in two car trains at an average speed of 12 mph (20
km/h).
DPM vehicles are self-propelled by Linear Induction Motors (LIM) powered by 3-
phase inverters. Power is derived through truck-mounted current collectors from
side-mounted 600 Vdc, nominal, power rail running parallel to the running-rails.
Trains are controlled from the central control system through the Vehicle-Onboard-
Computer (VOBC).

1.3    BASIC DESIGN CONSIDERATIONS

Overhauled DPM vehicles shall meet all original performance operating parameters.
Overhauled DPM vehicles shall be capable of providing a minimum of 20 years
additional service averaging 36,000 miles (58,000 km) of service each year without
further rehabilitation.
All overhauled DPM vehicles provided to DTC pursuant to this contract shall be
identical in configuration. Complete interchangeability among all overhauled DPM
vehicles shall be provided to the greatest extent possible. Records for each vehicle
documenting these identical configurations shall be provided by the Contractor.
Where a component or assembly is specified to be repaired, overhauled,
reconditioned, or renewed, the Contractor may propose equivalent replacements.
The phrase “as required” shall be interpreted to mean “as required to meet the intent
of the specification including all aspects of this section”.
All consumable parts (filters, hoses, brake pads etc.), all gaskets and all rubber or
elastomeric parts, shall be replaced with new original manufacturer (OEM) approved
materials.
All missing or damaged hardware and parts shall be replaced with equivalent new
material. Car 12 is currently missing major subassemblies and has been out of
service for over 6 years. Installation of missing components for Car 12 shall be part
of this contract. For estimating purposes, the Contractor (Bidder) shall assume that
Car 12 is complete.
During the outbound joint inspection, missing items are to be noted on the inspection
report. DTC, at their convenience, will either provide replacements for missing
components or issue a Change Order for the Contractor to provide and install the
missing material. Components specified to be renewed or replaced under this
contract shall be excluded from the inspection report and shall be the Contractor’s
responsibility.




Issue Date: 3/28/05                    1-4
IFB 4-002 TECHNICAL SPECIFICATION                                          1 - GENERAL


The Contractor shall ensure that in the final product, there shall be no sharp or
burred edges or corners at any place in the car where passengers, crew or
maintenance personnel may become injured.
Adequate clearances shall be provided between vehicles, and between carbody,
subsystems and trucks where modifications are made.
Any new apparatus or subsystem supplied as part of the overhaul work shall be the
same for all vehicles and shall be fully interchangeable.
Copies of all available manuals and drawings shall be provided to the successful
bidder upon request after the contract has been awarded.

1.4       STANDARDS

The equipment and materials provided by the Contractor shall comply specifically
with the requirements of APTA and all applicable state and local codes in effect at
the time of submission of the proposal by the Contractor. The Contractor shall notify
DTC in the proposal of any pending changes to these requirements.
If a conflict is discovered among any of the above requirements, the order of priority
listed below shall govern. In the event of such conflict, the Contractor shall notify
DTC promptly for resolution:
      •   FTA
      •   Laws of the State of Michigan
      •   ADA
      •   Contract
Trade names and/or manufacturer’s names and part numbers shown throughout this
specification are not “Sole Source Items”. They are identified herein to denote the
quality and performance of the desired product and to identify those specific items
that have successfully met DTC operating requirements for reliability, maintainability,
life expectancy, and interchangeability. DTC considers these items or products as
approved for use on the DPM vehicles. The Contractor may opt to use an equivalent
product with the prior approval of DTC. It shall be the sole responsibility of the
Contractor to submit sufficient evidence to DTC to prove product equivalency. DTC
may, without giving cause or reason, either approve or disapprove the substitution of
materials.

1.5       MAINTAINABILITY

Maintainability of DPM vehicles and associated equipment shall be given prime
consideration by the Contractor in the overhaul of the vehicles and by the
Contractor’s vendors in the fabrication, assembly, or overhaul of individual
subsystems and components.




Issue Date: 3/28/05                       1-5
IFB 4-002 TECHNICAL SPECIFICATION                                      1 - GENERAL


Maintenance cycles shall conform to original OEM recommendations. Vehicles
currently receive periodic maintenance on a 30 day cycle with the work scope of
each 90 day increment being more intensive.
DTC is planning to schedule maintenance on an operating time basis, based on 500
hour increments. Planned operating hours are 8 cars operating 16 hours per day.

1.6    WEIGHTS AND DIMENSIONS

The empty weight of a DPM vehicle delivered new was 32,200 lbs (14,600 kg).
There shall be no weight penalties assessed for any weight increases in overhauled
DPM vehicles.
Each vehicle shall be weighed prior to overhaul and at the completion of overhaul
and the weight tickets shall be included in the Car History Book.
The Contractor shall weigh the second overhauled vehicle and any subsequent
option vehicles on level tangent track to determine the end-to-end and lateral
imbalance.
       Dimension                                     Inches     Millimeters
       Length, over coupler pulling face               500.0”   12,700 mm
       Length, between truck centers                   312.6”    7,940 mm
       Width of Vehicle                                98.4’’    2,500 mm
       Height, ATR                                     123.0”    3,125 mm
       Height, floor ATR                               30.0”      762 mm
       Width, side door opening                        48.0”     1,220 mm
       Height, side door opening                       74.9”     1,920 mm
       Width, end door opening                         27.4”      700 mm
       Height, end door opening                        70.4”      805 mm
       Headroom, center aisle                          81.1”     2,060 mm
       Height, Coupler centerline ATR                  21.0”      535 mm
       Truck wheel base                                67.0”     1,700 mm
       Wheel diameter, new                             18.1”      460 mm
       Wheel diameter, worn                            17.3”      440 mm
       Track gauge                                     54.5”     1,386 mm
                           Chart 1.6-1 Pertinent Dimensions




Issue Date: 3/28/05                     1-6
IFB 4-002 TECHNICAL SPECIFICATION                                          1 - GENERAL


1.7    DEFINITIONS

        TERM              DEFINITION
        Accepted      or An item which is fully interchangeable in terms of form, fit,
        Equivalent       function, and properties to the specific item. Any proposed
                         accepted equivalent shall be submitted to DTC for review
                         and approval.
        Add               The inclusion of a specific item in the car configuration,
                          which is not currently installed.
        Approved      or DTC considers the item accepted for use on the DPM
        Approval         vehicles
        Modify            Change the design, placement, or other aspect(s) of an
                          item to provide for a different form, fit or function or to
                          overcome shortcoming(s).
        New               An item which has not previously seen service in whole or in
                          part.
        No Action         An item that requires no specific work as part of the
                          refurbishment. The removal, re-installation, or other
                          manipulation of any such item may still be required to
                          perform the other required work.
        Recondition       The restoration of an item to have the performance, service
                          life, and appearance of a new item through the replacement
                          of worn parts, adjustments, cleaning, refinishing (i.e.
                          painting, polishing, anodizing, etc.), repair of any damage,
                          and any other rehabilitation work required. When an item is
                          beyond reconditioning, it shall be renewed.
        Remove            The elimination of an item from the final car configuration.
                          The removal of any such item shall include all other work
                          required to ensure that the final car configuration does not
                          reflect any of the original item installation (such as wiring,
                          holes, brackets, etc).
        Renew             The installation of an identical but new item.
        Repair            The fixing of specific damage. Items which are beyond
                          repair shall be renewed.
        Replace           The installation of a new but different model or design of an
                          item in lieu of the one used currently. The replacement of
                          any such item shall include all other work required to ensure
                          that the final car configuration does not reflect any of the
                          original item installation (such as wiring, holes, brackets,
                          etc).



Issue Date: 3/28/05                     1-7
IFB 4-002 TECHNICAL SPECIFICATION                                        1 - GENERAL


1.8    DISPOSITION OF REMOVED MATERIALS

Materials and components removed for the purposes of modification and upgrades
to DPM vehicles and systems shall be retained, with the exception of fasteners,
insulation and other inconsequential and/or non-reusable materials. Care shall be
rendered by the Contractor to avoid damage caused by the removal process or other
activities. These materials shall be placed on pallets for review and disposition by
DTC. Following DTC disposition of the first car set of removed materials, a
disposition decision will be rendered regarding the handling of the remaining car
sets.

1.9    EQUIPMENT NUMBERS

The Contractor shall be responsible for prominently labeling all vehicles and parts
thereof with the appropriate Road Numbers throughout the process.
The original Road Numbers, Numbers 01 through 12, shall be retained.
The Contractor shall maintain a record, in the Car History Book, of each vehicle’s
original Road Number and any newly assigned Road Numbers.

1.10   MANUALS

DTC will provide a copy of the original maintenance, parts and operators manuals to
the successful bidder in CD format upon request after contract award.
                                  End of Section




Issue Date: 3/28/05                   1-8
IFB 4-002 TECHNICAL SPECIFICATION                           2 – QUALITY ASSURANCE



SECTION 2             INSPECTIONS, TESTS, QUALITY ASSURANCE
2.1    GENERAL

Quality assurance, inspection and testing of each vehicle and its components is the sole
responsibility of the Contractor.
DTC will provide QA personnel to monitor Contractor and Subcontractor work in
progress. The presence of DTC representatives at Contractor or Subcontractor
manufacturing facilities shall not in any manner supplant the Contractor's QA
obligations or lessen the responsibility of the Contractor in respect to meeting all the
requirements of the Specification. The cost of DTC inspection personnel will be the
responsibility of DTC. No provision for these costs shall be included in the offeror's
proposal.
In-process inspections and tests shall be performed in accordance with procedures
prepared by the Contractor and accepted by DTC. DTC may witness any or all of these
inspections and tests on a continuous or intermittent basis, and may, at its election
perform independent inspections.
The Contractor shall maintain a Quality Assurance program approved by DTC.
Selected materials, components and subsystems shall be subject to a First Article
Inspection. Material acquired and installed prior to receiving first article shall be done
strictly at the Contractor's risk.
Selected systems shall require a proof of performance test in accordance with DTC
approved procedures.
All systems shall be thoroughly tested in accordance with DTC approved procedures
either in the Contractor’s manufacturing facility or on the DTC system prior to releasing
overhauled DPM vehicles for passenger service.
Testing on DTC track is limited to the hours of 12 midnight to 5:00 AM. No other track
testing will be permitted. These tests shall be conducted by and at the expense of the
Contractor. The Contractor shall assign a competent representative to witness such
operating tests. Any defects disclosed by such tests, in apparatus, material, or
workmanship shall be corrected at the Contractor's expense.
Written reports of all tests performed on the DPM vehicles and their components shall
be submitted to DTC. Tests required by the Specification which are performed on all
DPM vehicles or all components shall be included in the Vehicle History Books.
The Contractor shall submit to DTC for approval, complete test procedures for each test
to be performed. Test procedures shall include the test objective, equipment to be
tested, instrumentation, pass/fail criteria, and data recording sheets. Procedures shall
be submitted in a timely manner to allow for review and approval by DTC. DTC will
make every effort to respond within thirty days of submittal.




Issue Date: 3/28/05                     2-1
IFB 4-002 TECHNICAL SPECIFICATION                              2 – QUALITY ASSURANCE


DTC shall be notified of the time and location of each test at least five (5) working days
prior to the scheduled test date. All tests shall be scheduled during normal weekday
daytime hours, excepting those requiring vehicle operations on the DPM system which
will be performed between the hours of 12:00 midnight and 5:00 AM. Alternative
arrangements shall require DTC approval.

2.2     QUALIFICATIONS TESTS (FIRST VEHICLE ONLY)

Qualification or proof of performance tests shall be required for all equipment or
subsystems that have not seen prior service on the DPM vehicles. The Contractor shall
provide a listing of anticipated Qualification Tests to DTC prior to the delivery of the first
vehicle to DTC.

2.2.1      Static Brake Test

A "force measuring brake shoe" shall be employed as a method of measuring shoe
forces on the first vehicle only.

2.2.2      Truck Clearance Test

Truck clearances, lengths and location of brake hoses, electrical jumpers, and coupler
and drawbar clearances and operation shall be demonstrated at the Contractor's plant
by moving a two vehicle train over curves and a crossover duplicating or exceeding the
most restricting trackwork on the DPM system or other approved method. Truck
clearance tests shall be performed on both trucks of each vehicle.

2.2.3      Lighting Intensity

Illumination levels shall be measured in aisle ways, vestibules and doorways and at the
platform level to verify compliance with the requirements of 49 CFR 38 and 49 CFR
238.
The tests shall simulate nighttime conditions at a non-lighted station of DTC’s choice
with the measured surfaces illuminated by vehicle borne interior lighting only.
This test shall be performed on the first vehicle at the earliest time practical.
Lighting fixtures shall be modified as necessary to meet the illumination requirements of
49 CFR 38 and 49 CFR 238.
Illumination shall be measured at the platform level with the side door in the open
position. Illumination level shall not be less than one (1) foot-candle measured at the
platform surface up to a distance of three (3) feet perpendicular to all points on the edge
of the side door.
Illumination shall be measured at the vehicle floor level, including all potential crew and
passenger evacuation routes. Illumination shall not be less than five (5) foot-candles.




Issue Date: 3/28/05                       2-2
IFB 4-002 TECHNICAL SPECIFICATION                          2 – QUALITY ASSURANCE


2.2.4      Paint Adhesion Test

The Contractor shall perform a Paint Adhesion Verification Test, paint peel test, using a
pressure sensitive tape similar to Permacel, New Brunswick, NJ, of paint samples
prepared at the time of painting the first Vehicle.


2.3     FIRST ARTICLE INSPECTIONS

Components shall be tested for proper function and operation to the maximum extent
possible at the manufacturing or overhaul plant before shipment. The Contractor shall
include these tests in the test plan. Components to be tested shall include, but not be
limited to:
      LED/LCD signs              Brake components             DC/DC Converter
      Communication controls     Door System                  Audio Announcements
      HVAC control panels        Interior Lighting            HVAC blower motor


Where applicable, first article inspections shall include functional tests demonstrating
proper operation across the operating range of the component or equipment.

2.4     STATIC TESTS (ALL DPM VEHICLES)

The Contractor shall statically test for functionality all systems on every DPM vehicle
before presenting the vehicle for final inspection prior to release for shipment.

2.4.1      Water Tightness Test

All areas of the vehicle sides, ends, and roof, including doors and windows on all DPM
vehicles shall be given a complete test for water tightness. The test shall be made after
all materials and components are removed for refurbishment. The test shall be repeated
again after repairs are completed, to confirm that repairs have corrected leaks.
The water shall be directed from nozzles toward the ends of the vehicles and over the
roof and sides.
Water pressure at the nozzle shall be 40 psi ( 275.5 kPa) minimum. Each nozzle shall
be rated to deliver a minimum of six (6) gallons of water per minute with a pressure at
the nozzle of 100 psi (689 kPa). Nozzle location shall be such that full overlap between
nozzle patterns is obtained on the surfaces of the vehicle body. Distance from nozzles
to vehicle surface shall be as required to obtain overlap but shall not exceed 60" (1524
mm).
All spray applications shall run for ten (10) minutes before the inspection for leaks
begins and shall run continuously during the inspection.
Underfloor boxes which are required to be watertight, shall receive a pressure water test
similar to the water tightness of the vehicle body.


Issue Date: 3/28/05                     2-3
IFB 4-002 TECHNICAL SPECIFICATION                                2 – QUALITY ASSURANCE


All air intakes and exhaust vents in the vehicle roof shall also be water tested.
Any area showing evidence of leakage shall be repaired to the satisfaction of DTC.
Other equivalent test equipment arrangements and values which have been
successfully used by the Contractor in similar applications will be given consideration.

2.4.2      Electrical Wiring Test

A Continuity Test shall be performed on all wiring before any testing or application of
electrical power. Confirm the accuracy of all wire labels as continuity is verified.
Make a direct current ground insulation test on each vehicle by disconnecting all ground
wires; and leakage test each nominal voltage circuit separately.
Make a high potential ground insulation test on all circuits and apparatus in each vehicle
at appropriately reduced voltage in accordance with IEEE standards, renew wiring
failing the pass/fail criteria.
All wires and cable that do not meet the requirement of the test shall be replaced by the
Contractor and retested.
Reconnect ground connections and then test all circuits on each vehicle for proper
functioning.
Components furnished by vendors that are assembled and wired into packaged units at
the point of manufacture shall be tested at the point of manufacture and a certified test
report concerning actual tests made on components being furnished for this Contract
shall be supplied to DTC, through the Contractor.

2.4.3      Train Line Test

The Contractor shall utilize an appropriate means to verify the accuracy of vehicle train
line connections. This test shall be made on each completed vehicle at both ends, and
in a two vehicle train.

2.4.4      HVAC Test

The Air Conditioning Tests shall include a functional check of all apparatus including
thermostats and controls with the equipment supplied with 600 Volts DC.
   •    The operation of all protective circuits shall be verified.
   •    Measurements shall be taken with the apparatus running at nominal voltage.
   •    The current drawn by the equipment and the line voltage shall be recorded
        during the testing.
   •    Controls and diffusers shall be checked and adjusted for even temperature
        distribution and proper circulation of air in all DPM vehicles while maintaining an
        acceptable noise level.
   •    Tests shall be performed on completed DPM vehicles.


Issue Date: 3/28/05                        2-4
IFB 4-002 TECHNICAL SPECIFICATION                            2 – QUALITY ASSURANCE


   •    Proper draining of the evaporator condensation pan shall be verified.
Heating Tests shall include functional checks of all apparatus including thermostats and
controls and including layover heat, and protective devices.
   •    Heating tests shall be run at nominal voltage 600 volts DC.
   •    The supply voltage and current demands of the equipment shall be measured
        and recorded.
   •    Arrangement of ammeters shall be such as to allow determination of the
        individual current demands of the floor heat and each overhead unit.
   •    Operation of floor heater fans and emergency ventilation fans shall be verified.
   •    Operation of the dampers shall be verified
   •    Tests shall be performed on completed DPM vehicles.

2.4.5      Brake Tests

The Contractor shall perform a brake functional test on each completed vehicle. The
brakes, and all associated apparatus and indicators shall be statically tested and
adjusted to function as specified.
The Contractor shall verify that all the brakes can be manually released and applied.

2.4.6      Weights

The Contractor shall weigh all DPM vehicles, at each end separately, with all equipment
installed, at shipment and furnish a weight ticket from certified scales or calibrated load
cells. The weight ticket shall be entered in the Vehicle History Book.

2.4.7      Door System

On each completed vehicle, the Contractor shall test the functional operation of the door
system, local and trainline operation, and door cycle operation and timing. The doors
shall be checked and adjusted on all DPM vehicles to ensure smooth functioning,
including operation and proper seal. The test shall include verification of compliance
with all applicable ADA door system requirements, including but not limited to door
closing annunciation, both visual and audio, closing times, closing forces and
emergency door releases.

2.4.8      Communications System

The Contractor shall test each completed vehicle to confirm the operation of the
communication system.




Issue Date: 3/28/05                      2-5
IFB 4-002 TECHNICAL SPECIFICATION                             2 – QUALITY ASSURANCE


2.4.9       DC/DC Converter

The Contractor shall functionally test the low voltage power supply (batteries and
rectifier/charger) on each completed vehicle. The test shall verify proper output voltage,
battery transfer and load shed functions, remote indicators, and all protective devices.

2.4.10      VOBC and ATC Systems

The contractor shall test the VOBC and ATC Systems statically in accordance with
OEM test procedures.

2.5      QUALITY ASSURANCE

The Contractor shall provide and enforce a Quality Assurance Program for in-house
work and for all lower tier subcontractors, including all of the materials and services
supplied by any or all of those subcontractors. The Contractor’s Quality Assurance plan
shall be submitted for DTC approval.
The Contractor shall ensure that all materials, workmanship and end products within the
scope of this procurement meet the contract requirements. For the purposes of this
contract, the following definitions will apply.
      Quality Program Audit: An audit of a particular company or facility to verify quality
      activities are compliant with the requirements of DTC approved quality program of
      that company.
      Quality Assurance Program: The overall program of a company to assure only
      products and services of acceptable quality are delivered to customers. The
      program is supplemented by the Quality Plan which is tailored specifically to the
      requirements of a particular project.
      Quality Plan: A specific document which is written under the umbrella of the
      Quality Program to address the requirements of a particular project or activity. The
      Quality Plan is written in greater detail than the Quality Manual and contains
      examples of inspection check lists, audit check lists, and test reports and other
      documentation necessary to verify the quality of the product. All of these
      documents are tailored to the specific project.
      Quality Manual: The written document of a company which describes its overall
      Quality Assurance Program activities and responsibilities.        This manual is
      augmented by the Quality Plan for each specific project. The Quality Manual serves
      as the foundation upon which the Quality Program, including the Quality Plan is
      constructed.
      First Article Inspection (FAI): An FAI is the complete and thorough inspection
      and verification of the first production article of any design for compliance with all
      applicable drawings, codes, specifications and workmanship standards. The FAI
      may include qualification or functional tests. The FAI establishes compliance with
      applicable documentation. It also establishes the standard of quality for additional
      production parts of that design.


Issue Date: 3/28/05                       2-6
IFB 4-002 TECHNICAL SPECIFICATION                             2 – QUALITY ASSURANCE


    Release For Shipment (RFS): A document which states that the subject
    components or products are complete and free of obvious discrepancies and are
    ready for shipment to DTC. Shipment of overhauled DPM vehicles shall not take
    place without an appropriately signed RFS.

2.5.1      Quality Assurance Program

The Contractor shall monitor and verify the acceptability of contractor and contractor
parts and services. This monitoring shall be accomplished by means of quality audits
(both internal and external), First Article Inspection (FAI), In-Process Inspection (IPI),
Pre-Shipment Inspection (PSI) and Receiving Inspection (RI). Various combinations of
these verification methods shall be utilized by the Contractor to an extent
commensurate with the criticality and complexity of the materials and services being
supplied. The Contractor's history, both prior to and on this contract, with that
subcontractor will be a factor in the determination of the level of inspection and
verification activities proposed for a particular subcontractor.

2.5.2      Quality Assurance/Quality Control

The Contractor shall submit for approval, within 15 days of NTP, a copy of its Quality
Manual. This Quality Manual shall describe the required quality activities of the
Contractor, assuring the appropriate quality level of materials and services for a vehicle
overhaul contract. The program shall require subcontractors to institute and follow a
quality plan which basically parallels, and is compatible with, the Contractor's Quality
Program.

2.5.3      Quality Assurance Plan

The Contractor shall submit to DTC for approval, within 45 days of NTP, a Quality Plan
designed specifically for this vehicle overhaul project. The plan shall be explicit and in
sufficient detail to preclude ambiguities. The Contractor's organization chart, including
the quality function, for this project shall be included in the plan. This organization chart
shall indicate names and titles in all key positions shown on the chart. The Contractor's
Quality department leadership assigned to this project shall have a reporting path to
corporate upper management, not program or project management of this contract.
DTC shall be notified in advance of changes in personnel, titles or organizational
structure. The plan shall include a complete listing of subcontractors and their supplied
materials, products or services, and shall indicate those subcontractors where a quality
audit will be performed, and those where he will conduct a First Article Inspection. All
subcontractors will be required to submit their quality plan for approval by DTC. This
subcontractor listing shall be submitted to DTC for approval. The plan shall also include
representative samples of check sheets, inspection reports and other quality
documentation forms to be used on this contract. The plan shall include provisions for
identification and segregation of non conforming materials including verification of
appropriate disposition of such non conforming materials.




Issue Date: 3/28/05                      2-7
IFB 4-002 TECHNICAL SPECIFICATION                           2 – QUALITY ASSURANCE


2.5.4      Subcontractor Control

DTC shall have the right to attend any and all visits by the Contractor to the
subcontractors except those visits of a strictly financial or contractual nature between
the Contractor and the subcontractors.
The Contractor shall notify DTC, in writing, at least 15 calendar days in advance of all
quality audits, first article inspections, in-process inspections and pre-shipment
inspections at subcontractors. DTC will determine whether it will attend these functions
and will notify the Contractor of that decision.
Subcontractors, manufacturers and suppliers of materials or components shall be
required to demonstrate compliance to the requirements of the Contractor's quality
assurance plan or their own quality assurance plan which shall not be in conflict with the
Contractor's plan.
The Contractor shall audit all major subcontractors and suppliers and document their
implementation of the appropriate quality plans.

2.5.5      Configuration Control

The Contractor shall submit for approval a Configuration Control Plan within 60 days of
NTP to be used during the conduct of this contract.
This Configuration Control Plan shall identify a system by which drawings, documents
and hardware are controlled in terms of release and latest revision identification.
This plan shall be structured in such a way as to allow clear and simple identification
and revision level of drawings, documents and physical components and assemblies.
The plan shall include a system for issuance of revised drawings and retrieval of
obsolete drawings.

2.5.6      Material Review Board

Non-conformances, discrepancies and rejected parts shall be reviewed for disposition
by a Material Review Board (MRB).
The MRB shall consist of Contractor personnel drawn from engineering, manufacturing
and other departments as appropriate for the particular non-conformance at issue.
DTC resident representative will participate in the material review process and will sign
the disposition form to indicate DTC concurrence with the disposition. A DTC
representative's signature will not be required on any material disposition of "scrap",
"complete an incomplete process" or "return to vendor".

2.5.7      Metrology

The Contractor's Quality Program shall include a calibration/metrology system




Issue Date: 3/28/05                     2-8
IFB 4-002 TECHNICAL SPECIFICATION                           2 – QUALITY ASSURANCE


This system will ensure that all tools and measuring and test devices which are capable
of calibration and are available for use in the Contractor and subcontractor's facilities
are currently calibrated.
The system shall also provide a means of identifying the calibration status of these
instruments or devices in such a manner that the status is obvious to an individual when
they attempt to make use of the device.
The calibration of such tools and devices shall be directly traceable to the National
Institute of Standards and Technology (NIST). Records of the calibration history and
current calibration status of each tool shall be available for review by DTC.

2.5.8      Manufacturing/Production

The Contractor shall have manufacturing/production instruction sheets and/or guidelines
for work throughout the course of the contract. A copy of latest revision shall be kept on
shop floor for reference of those performing work. These instructions/guidelines shall
include, as a minimum:
    •   Electrical components, handling/installation/test.
    •   Wiring; routing, bundling terminations.
    •   Mechanical applications/torque limits/fastener requirements.
    •   Assembly/installation/adjustment instructions.
    •   Soldering instructions/techniques.
    •   Fiberglass/Body repair instructions/techniques
    •   Flooring rubber application instructions/techniques

Modifications to DPM vehicles after production require approval of DTC. Written FMI's
must be written and submitted to DTC for approval before beginning work on DPM
vehicles.

2.5.9      Special Processes

The Contractor shall have documented instructions or guidelines in accordance with
established industry practices or documents for use in the performance of special
processes and procedures. These processes and procedures shall include as a
minimum:
    •   Magnetic Particle examination
    •   Dye Penetrant examination
    •   Radiographic examination
    •   Welding (fusion or resistance)

Personnel performing special processes shall be qualified and certified in accordance
with applicable industry codes and standards.




Issue Date: 3/28/05                      2-9
IFB 4-002 TECHNICAL SPECIFICATION                              2 – QUALITY ASSURANCE


All welding and brazing shall be done by properly qualified welders certified by the
American Welding Society (AWS). All inspection of welding or brazing shall be done by
or under the supervision of an AWS Certified Welding Inspector (CWI).

2.5.10     Purchased Materials

To the extent practical for this contract, the Contractor shall establish procurement and
performance specifications for use by the Contractor, subcontractors, manufacturers
and suppliers to ensure compliance with quality requirements and contract specification.
All material certifications and test reports used as a basis for accepting materials shall
be retained by the Contractor and incorporated into the vehicle history book.
The Contractor shall control all materials during storage and handling to prevent
damage or deterioration. This control shall include:
    •    Identification and rotational control of limited shelf life items. Items with a
         specified shelf life shall be clearly and permanently identified with a use by date.
    •    Proper handling, use and disposal of environmentally hazardous materials.
    •    The Contractor shall clearly identify, segregate, document and disposition non-
         conforming materials.

2.5.11     Inspection Plan

The Contractor shall prepare an inspection plan showing major manufacturing and
inspection milestones for DTC approval.
    •    This plan shall include a flow chart of key manufacturing activities and shall
         indicate the Contractor's proposed inspection points.
    •    The proposed inspection points shall indicate the type of activity (on-line in-
         process, pre-shipment hold points).
    •    The Contractor shall submit to DTC for approval, at least 45 days prior to
         scheduled use, individual inspection procedures for each of the inspections
         indicated on the manufacturing and inspection flow chart.
    •    The plan, flow chart and individual inspection procedures shall be incorporated
         as a part of the Contractor's Project Quality Plan.

Joint inspection of DPM vehicles and documentation of condition, prior to
commencement of overhaul activities, shall be included as part of this plan.
The inspection plan shall be used by DTC to identify inspection, witness and hold points
to be observed by DTC and the Contractor.
The Contractor shall ensure that all processing, fabricating and other production
operations shall be accomplished under an in-process inspection and/or production
control system.
The Contractor shall prepare a test plan identifying each test required by the contract
and the point in time or manufacturing sequence at which it will be performed.


Issue Date: 3/28/05                      2-10
IFB 4-002 TECHNICAL SPECIFICATION                          2 – QUALITY ASSURANCE


      •Each test shall be performed in compliance with a written test procedure
       prepared by the Contractor and approved by DTC.
   • The test procedure shall include pass/fail criteria defined by industry codes and
       standards or by this specification.
   • Test record and inspection records shall show numerical results, as well as the
       pass/fail determination.
The Contractor's inspection plan shall provide adequate surveillance to ensure proper
handling, storing, marking and packaging of items during the production process.
The Contractor shall eliminate system conditions adversely affecting product quality
through program effectiveness reviews and documented procedures that require
evidence of corrective actions taken to preclude the recurrence of identified
deficiencies.
The Contractor's inspection plan shall require inspection immediately prior to shipment
of items deliverable under this contract. This pre-shipment inspection shall include
verification that records documenting adherence to the inspection plan during
production are complete. These records shall include results of examinations, tests,
inspections, process controls and all other quality control requirements of the contract.
These records shall be maintained in an orderly, easily accessible arrangement, and
shall be available to DTC at all times during the contract.

2.6       DTC PARTICIPATION

DTC will conduct a quality audit of the Contractor and its facilities to verify the
Contractor's ability to perform the work required by this contract. The audit will verify
compliance with the Contractor's previously submitted and DTC approved Quality
Program including the Quality Plan for this contract.
DTC retains the right to witness or waive participation in all inspection activities at
Contractor, subcontractors, manufacturers and suppliers.
DTC retains the right to reject items found to be in non-compliance to the contract
specifications, industry practices, procedures and documentation, irrespective of
whether the non-compliance occurs or is discovered at Contractor, subcontractor,
manufacturers or suppliers facilities during the course of this contract.
If DTC elects to examine work partly or fully completed by a manufacturer or the
Contractor, the Contractor or manufacturer shall furnish the tools, instruments and labor
to perform such examination and inspection as may be required by DTC. Non-compliant
workmanship or materials which are disclosed shall be corrected promptly.




Issue Date: 3/28/05                    2-11
IFB 4-002 TECHNICAL SPECIFICATION                             2 – QUALITY ASSURANCE


DTC may choose to place occasional or long term resident quality personnel in the
Contractor's and/or the subcontractors' facilities to monitor the activities attendant with
the completion of this contract. All representatives of DTC shall be given free access to
all parts of the Contractor's facility where work on or for this contract is or will be
performed. DTC representatives shall not cause disruption nor interfere with production
activities in the course of exercising such free access. DTC inspection and/or
acceptance of components or products does not relieve the Contractor of the
requirements of this contract and his responsibility for the form function and quality of all
components parts and workmanship under this contract.

2.7       SHIPMENT AND ACCEPTANCE

All expenses incurred in preparing and moving DPM vehicles and materials to the
Contractor’s Manufacturing Facility shall be the responsibility of the Contractor. DPM
vehicles operate on an elevated rail system with no rail access to grade levels.
DPM vehicles shall be shipped from the Contractor's plant F.O.B., at no cost to DTC, to
DTC Maintenance Facility in Detroit, Michigan. Each overhauled DPM vehicle shall be
received on its own wheels on the tracks at DTC Maintenance Facility in Detroit,
Michigan
All costs of transportation, loading and unloading, including additional materials to be
supplied by the Contractor (including cranes and crane operators) shall be the
responsibility of the Contractor.
Spare parts and material shall be shipped to DTC prepaid. Shipments may commence
with Notice-To-Proceed.
The first DPM vehicle will be available for removal by the Contractor within sixty (60)
days upon issuance of Notice to Proceed.
The second DPM vehicle will available for removal by the Contractor no earlier than
March 1, 2006. DTC may opt to make up to four DPM vehicles available to the
Contractor at any given time. Additional vehicles will be released to the Contractor, on
a one-for-one basis, upon Delivery and Acceptance by DTC of each overhauled vehicle.
Each DPM vehicle shall have a joint pre-shipment inspection prior to release to the
Contractor, to note any defects or missing parts. The inspection report shall be jointly
signed by DTC representative and the Contractor representative. The reports shall
highlight any extra work items.

2.7.1       Receiving Inspection at Contractor Facilities

Upon receipt of vehicles at the Contractor's facility, Contractor and DTC representatives
shall perform a joint inbound inspection to document the condition of each vehicle prior
to its overhaul. Responsibility of all inspections is the Contractor's.
      •   Structural damage, missing parts and the general condition of the vehicle shall
          be recorded on large scaled diagrams by the Contractor.



Issue Date: 3/28/05                     2-12
IFB 4-002 TECHNICAL SPECIFICATION                           2 – QUALITY ASSURANCE


    •   A check sheet and procedure shall be prepared as part of the Contractor's
        Quality Assurance Plan.

All receiving inspections shall be conducted and completed on Mondays through
Fridays during daylight hours only, except holidays.
A Receiving Inspection Report, listing all such damage, loss, vandalism, or other
discrepancies, shall be prepared and signed by the Contractor's representative(s),
DTC's representative(s), and the Carrier's representative(s).

2.7.2      Certificate of Inspection and Release for Shipment

Prior to shipment of the overhauled DPM vehicles to DTC, a final in-plant inspection of
the vehicles and a review of its documentation shall be performed by DTC.
At this time, the Contractor shall have compiled, for review by DTC, the documentation
of all tests, inspections, serial numbers, weights, etc. to be entered into the individual
Vehicle History Book.
The Contractor shall allocate at least two (2) full (8-hour) working days, which shall be
weekdays during daylight hours, for DTC to perform and complete the review and
inspection. The inspection facility shall supply adequate protection from outside
weather, with the coach located over a pit having adequate illumination, with 600 Vdc
station power applied, for each Vehicle ready for shipment to assure it totally meets
Specification requirements and is fully operational.
On successful completion of inspection and review, a Certificate of In-Plant Inspection
and Release for Shipment will be issued by DTC to accompany the shipment of each
DPM vehicle.
All parts that must be removed to permit shipment and those items not permanently
secured to the vehicle shall be securely boxed to prevent damage and shipped in the
locked vehicle to which they belong. The parts shall be inspected and their securement
approved by DTC representative prior to shipment
In the event that DPM vehicles are complete and ready for shipment prior to the delivery
dates specified in the Contract, the Contractor shall so notify DTC. At DTC’s option,
said DPM vehicles may be shipped.

2.7.3      Receiving Inspection at DTC

Each overhauled DPM vehicle shall be received      on its own wheels on the guideway
tracks at DTC Maintenance Facility in Detroit,     Michigan and will then be visually
inspected jointly by representatives of DTC,        the Contractor and the Carrier’s
representative for damage, loss, vandalism, or     other discrepancies incurred during
shipment or hoisting onto the DPM guideway.
All receiving inspections shall be conducted and completed on Mondays through
Fridays during daylight hours only, excepting holidays.



Issue Date: 3/28/05                    2-13
IFB 4-002 TECHNICAL SPECIFICATION                             2 – QUALITY ASSURANCE


DTC will then issue a “Receiving Inspection Report” to the Contractor to acknowledge
receipt of the DPM vehicle and furnish appropriate notation as to its apparent “As-
Received” condition. The “Receiving Inspection Report” shall be signed by DTC’s
representative, the Contractor’s representative and the Carrier’s representative to attest
to the stated condition of the Vehicle.
Unless specifically excepted by the Contract Documents, and additionally at the sole
discretion of DTC, each Vehicle shipped from the Contractor’s plant to DTC shall be
complete, ready-to-run.

2.7.4      Conditional Acceptance

Following acceptance of the Receiving Inspection Report by DTC, the Contractor shall
prepare the vehicle(s) for road service.
As soon as possible after the Receiving Inspection, the Contractor shall adjust, repair,
or replace as required to correct, to the satisfaction of DTC, any discrepancies noted in
the Receiving Inspection Report.
Due to the regular maintenance demands on DTC facilities and maintenance personnel,
it will be possible for said personnel to undertake only minimal adjustment, repair, or
replacement work on equipment prior to Final Acceptance.
All work performed by DTC which is outside the scope of normal maintenance and
service shall be directly billed to the Contractor by DTC.
The Contractor shall therefore, in such event, be responsible for securing facilities and
personnel to complete all additional work, including retrofit program(s) if required, for the
duration of the contract.
Any defects in apparatus, material, or workmanship disclosed by inspections or tests,
shall be corrected at the Contractor's expense prior to Final Acceptance.
All expense and costs incurred in the removal of vehicle(s) to and from the designated
delivery point for correction of defects shall be borne by the Contractor.
Upon completion of the preparation of the vehicle(s) for road service and acceptance by
DTC, a Certificate of Conditional Acceptance shall be prepared and signed by DTC's
representative(s).
The Certificate shall note any discrepancies remaining to be corrected by the
Contractor.

2.7.5      Conditional Acceptance Tests

DTC will provide a system operator at no cost to the Contractor for a period not to
exceed a total of 30 work days, for acceptance track testing of overhauled DPM
vehicles. A “work day” shall comprise of one week day, excluding holidays, between the
hours of 12:00 midnight and 5:00 AM. Additional test time shall be at the Contractor’s
expense.




Issue Date: 3/28/05                     2-14
IFB 4-002 TECHNICAL SPECIFICATION                             2 – QUALITY ASSURANCE


The Contractor shall be required to functionally test all vehicle systems and subsystems
to assure and document the functionality and performance of each vehicle, in
accordance with the Specifications and DTC O.E.M. Operating and Maintenance
Manuals.
Acceptance Test procedures shall be submitted to DTC for review and acceptance at
least thirty (30) calendar days prior to the scheduled start of any tests.
Reports of all tests shall be submitted for review and acceptance by DTC prior to final
vehicle acceptance.
The Contractor shall be responsible for costs of preparing DPM vehicles for test.
Contractor shall provide all necessary personnel and instrumentation to measure
system and performance parameters.
All charts or data recorded shall be treated for permanence, and shall become the
property of DTC.
DTC shall be responsible for determining each vehicle's readiness for normal operation
in revenue service.

2.7.6       Final Acceptance

Final acceptance of overhauled DPM vehicles shall be based on the following criteria:
      •   All contractual and workmanship deficiencies discovered during inspections of
          the vehicle shall have been corrected by the Contractor in a manner judged
          satisfactory to the Contract requirements.
      •   Submittal by the Contractor to DTC of all required test reports, showing that all
          tests and inspections have been successfully completed.
      •   Complete documentation, as applicable to historic record keeping of work
          performed in compliance to Contract.

A Certificate of Acceptance signed by DTC representative and the Contractor
representative shall be issued after satisfactory completion of all inspection and test
criteria.

2.8       RECEIPT OF CONTRACTOR FURNISHED MATERIALS

All Contractor furnished materials, including but not limited to spare vehicle parts,
components, sub-assemblies, warranty material, tools or equipment, manuals or other
materials or items to be supplied in conformance with this Contract shall be delivered to
the DTC Maintenance Facility in Detroit, Michigan.
Notwithstanding the foregoing, the Contractor shall bear all risks of loss of each item
until the same is delivered to DTC as designated above.
On receipt of any such report which indicates a short shipment or damage item, the
Contractor shall promptly replace any missing or damaged equipment and material to
prevent delay of the project.


Issue Date: 3/28/05                      2-15
IFB 4-002 TECHNICAL SPECIFICATION                          2 – QUALITY ASSURANCE


Promptly” means in-stock items shall be shipped immediately while the remanufacture
and/or re-purchase of all other items shall be initiated without delay.

2.9    STORAGE OF MATERIALS

All materials intended for use by the DPM vehicles shall be marked and stored in the
Contractor’s plants as to be readily identified and shall be adequately protected during
handling and storage.


                                  END OF SECTION




Issue Date: 3/28/05                   2-16
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP



SECTION 3             MATERIALS AND WORKMANSHIP
3.1    GENERAL

The Contractor shall use materials, standards and workmanship as specified in this
section to renew, in-kind, hardware, components and systems during the overhaul of
the cars. Unless otherwise stated or where damaged beyond repair, existing hardware
and materials may be revised after suitable cleaning and repair. The intention is that
the cars will functionally be in like-new condition and aesthetically refurbished after
completion of the overhaul.
All materials used in the refurbishment and construction of these passenger cars shall
be generally accepted in the industry and conform to the requirements of this
specification.
All workmanship shall conform to the best manufacturing practices in all respects.
This section shall be applicable to all new or refurbished work applied to or installed on
the passenger car whether furnished by the Contractor or by any of his/her suppliers.
Replacement of parts in-kind from OEM or other authorized suppliers with ISO 9000
certification is deemed to be in compliance with this section.
Materials or equipment substitutions proposed by the Contractor shall be secured by
written approval of DTC prior to making the substitution.

3.2    STANDARDS

Unless otherwise specified, all materials shall conform to NFPA, AAR, APTA, ANSI,
ASCE, ASME, AISI, IEEE and/or ASTM Specifications.
Threaded fastenings and other standard machine elements shall conform to ANSI
standards.
Metric threads shall not be used without written DTC approval for each specific
application. Metric threads may be used, without prior DTC approval, for renewal of
existing metric fasteners.
Inclusion of a material or method in this section does not indicate approval for
application or use in a specific situation. When a material or method is specified in this
section, this section shall be applicable. However, specific requirements detailed in the
appropriate Technical Specifications take precedence over this section.

3.3    MARKING

All new materials intended for use on these passenger cars or material removed during
the overhaul and intended to be reused, shall be marked or stored so as to be readily
identified, and shall be adequately protected during handling and storage.
Rejected material shall be clearly marked and stored in an area specifically designed for
that purpose. Rejected material shall remain “unavailable for use” until documented
disposition is approved by DTC.

Issue Date: 3/28/05                     3-1
IFB 4-002 TECHNICAL SPECIFICATION                   3 - MATERIALS AND WORKMANSHIP


3.4     TRIM FINISH

All exposed interior metal trim shall have a satin finish except the heater guards and
exposed portions of the stainless steel structure, which shall have a 36-grit-sanded
finish and all non-corrugated exterior stainless steel surfaces shall have a fine grit-
sanded finish, unless otherwise specified.

3.4.1        Lumber

Lumber shall be thoroughly air-seasoned or kiln-dried before using, dressed on all
surfaces to full dimensions, and treated to meet the flammability requirements

3.4.2        Plywood

All plywood shall be manufactured to conform to the requirements of Grade-Structural I
of the American Plywood Association Specification PS1 and then stored under cover.
All plywood panels shall be sealed with aluminum lacquer on all edges and cutouts as
soon as possible after fabrication.
All exposed edges of the panels, joints between panels, fastener heads, and openings
in panels used in areas accessible to moisture, shall be waterproofed and sealed in a
manner approved by DTC at time of application.

3.4.3        Plymetal

The term "plymetal" as used in this Specification means 'Structurally bonded plymetal
panels' complying with the following specifications and U.S. Mil-P-8053.
        •    Test Conditions (Minimum Metal to Wood Shear Value or 80% Wood Failure)

            Dry Shear:                                                 250 psi
            Boil shear, 3 hr. boil, tested wet at room temperature:    150 psi
            Soak shear, 48 hr. soak, tested wet at room temperature:   150 psi
            Creep or cold flow, under static load for 48 hrs, at room 250 psi
            temperature:


        •    Tensile Strength

        Panel specimens shall be tested for tensile strength in flat plane in compliance
        with requirements of ASTM-C297. Sandwich panel material shall be rejected if
        tensile failure occurs in bond between facing and core.
When finished, continuous edge reinforcement shall be incorporated to facilitate transfer
of stresses and to seal edge against moisture penetration and other damage.



Issue Date: 3/28/05                        3-2
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


3.4.4      Asbestos

The use of asbestos or asbestos-based products in any portion of the reconstruction of
these passenger cars is specifically prohibited.
There is not known use of any asbestos in the original construction of the cars.
However, The Contractor shall conduct independent tests on any materials that might
contain asbestos to ascertain the presence or absence of asbestos in order to comply
with the applicable federal and state regulations governing exposure, abatement and
disposal. The Contractor shall advise DTC after stripping the first car, if any asbestos is
found.

3.5     JOINTING AND FASTENINGS

Certain combinations of materials shall require particular care in joining to avoid the
possibility of dissimilar corrosion materials.
Extreme care shall be exercised in joining materials or components to ensure that the
finished product is free from rattles and objectionable noises.

3.5.1      Fastenings

All new fasteners must meet the requirements of 15 CFR Part 280, Fastener Quality.
No protruding screws, mounting bolts or similar items shall be permitted either on the
interior or exterior of the passenger car, other than those appointments, which can be
built into the structure in no other manner.
All exposed flat, pan, or oval head screws shall be stainless steel, unless otherwise
specified.  Fasteners exposed to passenger access shall be tamper resistant.
Fasteners not exposed to passenger access shall be of the cross-recessed type.
At least 1½ screw threads shall be visible beyond all nuts. When used without elastic
stop nuts, bolts shall not project more than 1 ½ threads plus ¼ inch (6 mm) for bolts ¼
inch (6 mm) diameter or less and shall not project more than 8 threads for larger
diameter bolts. With elastic stop nuts, bolt threads shall not project more than ¼ inch
(6.4mm), regardless of bolt size.
Screws, bolts and nuts shall conform to American National Standards and shall be zinc-
plated or approved equivalent, unless otherwise specified.
Self-locking nuts shall be used throughout where practical.
Self-tapping screws shall not be used in the areas requiring dismantling for servicing.
When bolts are used to secure apparatus and the bolt head is inaccessible, a
mechanical locking device shall be used to prevent the bolt head from turning when the
nut is being applied or removed.
When nuts are inaccessible, a mechanical locking device shall be used or the nuts may
be carefully welded in place.



Issue Date: 3/28/05                     3-3
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


Where rows of inaccessible bolt fastenings are required, a tapped stainless steel plate
with a minimum thickness of 0.375 inches (10 mm) shall be welded to the supporting
structure.
All holes shall be drilled using the minimum practical hole size compatible with fastener
employed.

3.5.2      HUCK Fasteners

HUCK fasteners may be used in locations approved by DTC. All rough surfaces of
collar end of HUCK Fasteners shall be ground smooth in maintenance access areas
only.

3.5.3      Torquing

All safety-related fasteners, including truck and brake equipment bolts and all fasteners
exposed to fatigue loads shall be torqued to a minimum preload equal to 75% of their
proof load and “torque striped” by paint or other approved method after being torqued.
All other fasteners shall be torqued so that they do not loosen in service.
Fastener installation torque for standard bolts with standard or heavy hex nuts may be
calculated from Industrial Fasteners Institute Fastener Standards (latest version),
equations using values for “K” of 0.18 for unplated, oiled or waxed threads and 0.15 for
plated threads that are also waxed or oiled. Locknuts shall be torqued in accordance
with their manufacturer’s recommendations or the Contractor may conduct tests to
determine installation torque. For special nuts or bolts requiring “torque striping”, bolt
torque-tension tests may be required to verify that the installed preload is equivalent to
75% of the proof loads.

3.5.4      Plating

Zinc plating conforming to the latest revision of ASTM Specification A165, Type NS
shall be required on fasteners not exposed to view. Cadmium plating shall not be used.

3.5.5      Cleaning

Where metal is welded, riveted, or bolted to metal in the passenger car structure,
contact surfaces shall be free of dirt, grease, rust, and scale and shall be coated, except
for stainless steel parts, with a suitable metal base primer which will not interfere with
later enamel or lacquer paint applications.

3.5.6      Metal-to-Metal Fastenings

Where metal surfaces are placed together for spot welding, an approved spot weld
primer shall be used. Stainless steel parts shall not require primer




Issue Date: 3/28/05                     3-4
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


3.5.7      Wood-to-Metal Fastenings

Where wood to metal surfaces are placed together, the wood is to be coated with
approved aluminum paint and the metal, except stainless steel, is to be coated with a
suitable metal base primer which will not interfere with later enamel or lacquer
application.

3.5.8      Wood-to-Wood Fastenings

Where wood surfaces are placed together, both abutting surfaces shall be coated with
approved aluminum paint.

3.6     COATING

When refurbishment, modification and/or replacement results in exposed surfaces of
uncoated metal except for stainless steel, it shall be given one (1) heavy coat of an
approved base primer and one (1) coat of an approved sealer.
All hidden wood shall be given a minimum of two (2) coats of aluminum paint (including
edges of ply-metal panels) to ensure sealing of surfaces.
Hidden metal and wood is material that will be subsequently covered by other materials
in the completed passenger car

3.7     SEALANT

Unless otherwise recommended by the sealant manufacturer, a single general purpose
sealing compound shall be used throughout the passenger car body.
The sealant shall have superior metal adhesive properties over which the specified
paints can be successfully applied.

3.8     STAINLESS STEEL

3.8.1      Type

This Specification covers AISI Types 201, 202, 301, 302, 304, 430 and Allegheny
Ludlum Type 363 stainless steels.
Only low carbon stainless steel shall be used for major structural fabrications and other
highly stressed components.
Certifications by the stainless steel supplier and its application by the Contractor (or
fabricator) shall be required.

3.8.2      Physical Properties

It shall be the responsibility of the Contractor to ensure that all material for each use
shall be of uniform strength and quality in accordance with AISI Standards.



Issue Date: 3/28/05                    3-5
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


3.8.3       Gauge Tolerance

Standard industrial tolerances or better shall be acceptable in material coils and sheets.

3.8.4       Buffing and Polishing

Buffing and polishing of stainless steel, where required, shall be done in an approved
manner and without the use of any composition containing iron or iron oxide.

3.8.5       Finish

Stainless steel in locations to be painted shall be given a #36 grit finish using a belt
sander or similar tool.
Stainless steel in locations to be unpainted shall be arranged with a brush finish
oriented in a horizontal direction on the exterior of the passenger car, and in a direction
to suit the decorative treatment in the interior of the passenger car, except for certain
vertical members such as doorframes.
Unpainted stainless steel frames, boxes, and other assemblies shall be constructed
from No. 1 or No. 2 matte finish sheets.

3.9      LOW ALLOY HIGH TENSILE STEEL

Low-alloy high-tensile (LAHT) steel, where used, shall be a nickel-containing low alloy,
corrosion-resistant steel with a high tensile strength.
LAHT steel shall conform to ASTM Specification A-242, and shall have a smooth
surface free from pitting.
Cor-Ten, furnished by United States Steel Corporation; Mayari R., as manufactured by
the Bethlehem Steel Company; Yoloy, as manufactured by the Youngstown Sheet and
Tube Company; Armco HT50, as manufactured by the Armco Corporation; Republic 65,
as manufactured by Republic Steel Corporation; or accepted equal, shall be acceptable
for such applications, except where a particular low-alloy high-tensile steel is called for
in this Specification.

3.10     STEEL CASTINGS

3.10.1      Quality

All new castings, unless otherwise specified, shall meet the requirements of AAR
Specification M-201 Grade B.
Steel castings shall be sound throughout within Specification requirements and/or for
the purpose intended.
The Manufacturer shall prove his manufacturing procedure by either destructive or non-
destructive means.




Issue Date: 3/28/05                     3-6
IFB 4-002 TECHNICAL SPECIFICATION                 3 - MATERIALS AND WORKMANSHIP


Following the establishment of a satisfactory test procedure, quality control shall be
maintained by testing one or more of each lot at a frequency mutual acceptable to DTC,
the Contractor, and the foundry. The test frequency shall be influenced by the critical
requirements of the part.
If new castings are found to be porous or otherwise unsound, the castings shall be
destroyed and replacements shall be provided at no cost to DTC.

3.10.2      Heat Treating

All new steel castings used in the truck structure shall be made of heat-treated electric
furnace or controlled open-hearth steel.
Where physical strength is gained by heat-treating, a physical test shall be conducted
on each treating charge, of each heat of castings.
Where more than one (1) heat is represented in a treating charge, a physical test shall
be conducted on each heat represented in each treating charge.

3.10.3      Other Castings

Steel castings used in locations not referred to herein shall be selected for composition
and characteristics best suited to the application, by the Manufacturer or Contractor
concerned, but shall be subject to review by the DTC.

3.11     MAGNETIC PARTICLE INSPECTION

Magnetic particle inspections of all surfaces of each casting to be conducted in
accordance with ASTM E personnel certified to MIL-STD-410. With respect to structural
castings, which include coupler, bolster, and truck castings, the maximum permissible
magnetic particle indication shall be ¼ inch in the direction transverse to the usual
direction of loading, and ¾ inch in the direction parallel to the usual direction of loading.

3.12     RADIOGRAPHIC INSPECTION

Radiographic inspection shall be conducted in accordance with the requirements of
ASTM standard E 94 using reference radiograph to ASTM E 446. A sampling
frequency shall be proposed by the Contractor and submitted for Engineer approval.
Structural castings shall not exceed severity level 3 of ASTM E 446 in all critical areas
of such castings and shall not exceed level 5 in all other areas of the castings.

3.13     WELDING

Welding required on castings is permitted provided the Contractor performs all weld
repairs in accordance with an approved written procedure and uses AWS certified
welders or welders qualified to ASTM A 488.
Prior to receiving approval, the supplier shall provide certified results for Weld
Procedure Qualifications, Personnel Qualifications and Materials and Equipment
Qualifications.

Issue Date: 3/28/05                      3-7
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


3.14     ALUMINUM

Aluminum alloy mill products shall be identified by Unified Numbering System
designations and shall conform to The Aluminum Association specifications contained in
the Association's publication “Aluminum Standards and Data." Aluminum alloy castings
used for door thresholds shall conform to ASTM 8-26,8-85, or 8-108 for, respectively,
sand, die, or permanent mold castings. Aluminum alloy forgings shall conform to ASTM
8-247. Copies of all test reports for sheet, extrusion, and forgings used in the car
structure shall be submitted to DTC.

3.14.1     Design Stresses

All aluminum structural members shall be designed so that calculated stresses under
the specified A W3 passenger load do not exceed the allowable stresses listed in the
latest revision of the Aluminum Association of America's “Specification for Aluminum
Structures " for bridge and similar type structures and " Engineering Data for Aluminum
Structures." Proper allowance shall be made for the effects of fatigue, for column and
plate stability effects, and for strength reduction at welded regions. Permissible fatigue
stresses under the specified A W3 passenger load shall be established, with approval
based on available relevant research data or on prototype testing under the variable
load patterns expected to occur in service.

3.14.2     Fabrication and Fastening

The forming of aluminum parts; joining of parts by bolting, riveting, and welding; and the
protection of contact surfaces shall, as a minimum, conform to the requirements of the
Aluminum Company of America's Technical Report No.524, "Specification Covering
Use of Aluminum in Passenger Carrying Railway Vehicles", except as otherwise
specified herein.
Fabrication techniques shall be such that the strength and corrosion resistance of the
aluminum shall not be impaired or the surface finish permanently marred or discolored
during construction.

3.14.3     Protection of Contact Surface

The specific measures to be taken by the Contractor to prevent the risk of direct metal-
to-metal contact and resultant possible electrolytic corrosion shall be approved and shall
depend upon the determination of the most suitable method that can be adapted to the
design involved. The following instructions shall be the minimum protection.
Aluminum alloy surfaces shall not be secured to or make direct contact with the
surfaces of copper, copper bearing aluminum alloy, brass, bronze, silver, nickel, nickel
alloys, nickel plated parts, lead, tin, or wood.
The contact surfaces of aluminum alloy with aluminum alloy shall be painted with zinc
chromate primer or approved equal before securing.




Issue Date: 3/28/05                     3-8
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


The surfaces of aluminum alloy parts secured to steel parts, where exposed to
weathering or harsh environments, shall be protected with a one-part polysulphide
sealant, zinc chromate paste, mica insulation joint material or an approved equivalent
material, which completely covers the faying surfaces. The insulating material shall be
non-hygroscopic and, if fibrous, shall be impregnated with bitumen or an approved, non-
corrosive, water and moisture-repellant substance. After driving, fasteners shall be
primed and painted with red oxide or aluminum paint.
Stainless steel and carbon steel fasteners plated with zinc shall be coated with zinc
chromate paste or approved equal before installation. Where possible, only the head
and the shank of the bolt shall be in contact with the aluminum part when secured in
place. Suitable bushings may be used in place of the zinc-chromate paste.

3.15   FIBERGLASS REINFORCED PLASTIC

Fiberglass reinforced plastic (FRP) panels or doors that are manufactured or modified
shall meet these requirements.
FRP shall be a glass-fiber reinforced laminated material composed of a gel-coated
surface with fiberglass reinforcement and a polyester resin.
FRP shall withstand, without any physical deformation or structural damage, the
environmental conditions and be resistant to cleaning solutions recommended by the
Contractor.
FRP shall meet the relevant flammability and smoke emission requirements.
The manufacturing process shall ensure that the glass fiber reinforcement is distributed
throughout the final product in such a manner as to avoid resin-rich or resin-starved
sections.
FRP parts shall be thicker at attachment points and edges.
Exposed sharp edges will not be allowed on any parts.
The resin shall be of good commercial-grade polyester material selected to meet the
physical properties and molding process requirements.
The fiberglass reinforcement shall be selected and the molding process requirements
with a minimum glass content of 20% by weight.
The gel coat shall be resistant to scuffing, fire, weather, and cleaning agents.
The gel coat shall have a minimum thickness of 0.015 inches.
If the surface of the FRP panel is to be painted, a primer gelcoat shall be used.
If the FRP panel does not receive paint, then the gelcoat is to be pigmented to match
the color selected by DTC.
Additives, fillers, monomers, catalysts, activators, pigments, fire retardants, and smoke
inhibitors shall be added to the resin to obtain finished products with the required
physical characteristics.



Issue Date: 3/28/05                      3-9
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


Mineral filler shall not exceed 28% of finished weight for any performed matched die
molding process.
Independent laboratory test certificates shall be provided stating the reinforced plastic
material complies with the requirements of the application.

3.16   INSULATION

Thermal and acoustic Insulation shall meet the smoke and flammability requirements as
noted below.

3.17   FLAMMABILITY, SMOKE AND TOXICITY

The Contractor shall meet the guidelines of NFPA 130 Fixed Guideway Transit
Systems, Current Edition, Chapter for Vehicles, including Recommendations for the
Testing the Flammability and Smoke Emission Characteristics of Rail Transit Vehicle
Materials. Independent laboratory certification shall be submitted for DTC review and
approval for all new materials used in the overhaul, indicating successful compliance
with the above requirements.
Oils and hydraulic fluids shall be flame retardant, except as required for normal
lubrication.

3.18   ELASTOMERS

All elastomeric parts specified herein shall be of neoprene, so compounded and cured
that it will perform satisfactorily in passenger car operation at any temperature between
-40°F and 120°F (-40°C and 48.9°C) and shall have the longest possible commercial life
consistent with the characteristics specified.

3.19   METAL PARTS

Unless otherwise specifically provided or agreed upon between the Contractor and
DTC, metal parts to which neoprene is cured shall be made of SAE 1020 hot rolled steel
and shall be suitable for brass plating after pickling.

3.20   SUBSTITUTE MATERIALS

Alternative materials will be considered provided the Contractor demonstrates to DTC
that the alternative material shall provide equal or better performance than the specified
material.

3.21   TRUCK PARTS

Truck bumpers and snubbers shall be made of neoprene conforming to ASTM
Specification D-735, Class SC-620 BEl E3 JFL.
Neoprene shall have the highest abrasion resistance possible consistent with all other
characteristics herein specified.


Issue Date: 3/28/05                    3-10
IFB 4-002 TECHNICAL SPECIFICATION                 3 - MATERIALS AND WORKMANSHIP


Neoprene shall be resistant to oil, grease, acid and other materials encountered in the
operating environment.
Natural rubber shall be considered an acceptable substitute for neoprene if certified to
resist contaminants.

3.22     GLAZING MATERIALS - GLASS

Safety glass shall be tested for optical deviation and visibility distortion in accordance
with ANSI Z26.1, Section 5.15.
All questions regarding the quality of safety glass shall be determined by the test
methods prescribed in ANSI Z26.1, Section 5.
All safety glass shall be marked with proper identification in accordance with ANSI
Z26.1, Section 7. The window light shall be installed so that identification markings can
be read from the inside, lower right hand corner.
All safety glass shall be of a high density laminated type conforming to DOT-22, AS-3-
84 and 66-M81.
All vehicle glazing shall meet the requirements of Automotive Safety Glazing, ANSI/SAE
J673 – APR93 (Edge Treatment) and Safety Glazing Materials for Glazing Motor
Vehicles and Motor Equipment Operating on Land Highways – Safety Standard,
ANSI/SAE Z26.1 – 1996. All windows shall meet Item 3 tests for glass and glass
laminates or Item 4 for rigid plastics.

3.23     HOSES PIPING & TUBING

3.23.1      Hydraulic Brake Hoses, Piping and Fittings

Hydraulic tubing and piping shall conform to ASTM A53 Schedule 40, or larger or
stainless steel tubing.
Joints shall utilize threaded or flanged fittings. Prior DTC approval shall be required for
lap-welded joints. Butt-welding shall not be permitted.
All piping shall be securely attached with clamps and insulators to prevent rattling.
Clamp and insulator spacing shall be sufficiently rigidity to avoid vibration.
Piping shall be installed to provide sufficient drainage to prevent freezing.
Truck piping shall be installed using a minimum of hose connections.
All piping shall be installed with the minimum number of fittings and in a manner
allowing for efficient maintenance.

3.23.2      Protection of Piping and Tubing

All piping and tubing shall be arranged and protected to the extent possible to prevent
damage caused by derailment, side-wipes, flying debris, and removal and replacement
of passenger car components.


Issue Date: 3/28/05                     3-11
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


In order to provide such protection, where not otherwise afforded by the passenger car
structure, stainless steel deflector brackets and plates shall be installed.

3.24     THREADED CONNECTIONS

The use of sealing tape (plumber's tape, Teflon tape, etc.) is specifically forbidden in
threaded pipe connections.

3.25     WIRE AND CABLE

All conductors shall be soft-annealed unalloyed copper tinned and stranded per AAR
Specification S502 (former No. 589), and jacketed with cross-linked polyethylene
(Flammanol XL) or radiation cross linked polyolefin (Exane) or DTC approved equal and
shall have properties and characteristics as specified in AAR Specification S501.

3.25.1     Heater Connections

Only high temperature insulated wire shall be used for interconnection of heater
elements and units.

3.25.2     Headlight and Resistor Connections

Wire shall be silicone insulated conforming to AAR Standard S-503.

3.25.3     Aluminum Wire and Cable

The use of aluminum wire and/or cable shall be specifically prohibited.

3.26     WIRING & CONNECTIONS

3.26.1     Application and Installation of Wire

All wiring shall be performed by or under the direction of experienced wiremen.
Wiremen shall be provided with appropriate tools for skinning insulation, cutting, tinning,
soldering, and attaching mechanical or compression type terminals to the conductors.
Care must be taken in removing insulation from the conductor to avoid nicking of the
wire or strands of the conductor cable.
Wire in ducts and conduit shall be free of kinks, insulation abrasions and insulation
skinning.
Passenger car wiring methods and materials shall be in accordance with Chapter 3 of
the National Fire Protection Association's Publication NFPA No. 70 (NECS) current
issue, except where otherwise required by the Specification, or where approved by
DTC, and except that all wire shall be stranded.
The layout of wiring shall be designed in advance of its installation and in cooperation
with those furnishing the related equipment.


Issue Date: 3/28/05                     3-12
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


Insofar as practicable, all wiring shall be fabricated on the bench into convenient units
and installed in prefabricated groupings and standardized locations.
All wire and cabling shall have appropriate service loops, drip loops, strain relief and
sufficient material for a minimum of three (3) re-terminations.
Spare terminations and conductors should be provided on terminal boards, in
connectors, and in wire bundles and multi-conductor cables between major panels and
junction boxes. A minimum of 10%, but not less than one (1), shall be provided.
Grounding connections shall be brazed and bolted to, or welded and bolted to, or silver
soldered and bolted to the passenger car frame.
All equipment enclosures and shock-mounted equipment shall be grounded with
flexible, strap-type, grounding leads bolted between a car body grounding pad and
equipment grounding pads.

3.26.2     Solder

Solder for electrical connections where permitted shall be in accordance with ANSI No.
1, Class B.
Non-corrosive flux shall be applied immediately before soldering.
An automatic temperature controlled solder pot shall be used.

3.26.3     Tape

Polyvinyl chloride or Nomex electrical tapes with Buna “S” type adhesive, 0.010 inches
(0.254 mm) in over-all thickness, or approved equal, shall be applied.
The above materials shall be suitable for use with the conductor insulation without
discoloring or corroding the copper wire and shall provide 600 volt minimum insulation.

3.26.4     Splices

Splices shall not be permitted.

3.26.5     Terminals

Conductors shall be fastened to terminals and connectors by accepted mechanical
methods. Soldering of conductors shall be allowed at selected locations only with prior
written approval of DTC.
Conductors, which will be subjected to motion relative to the terminal, shall be protected
by suitable means to minimize breakage of the conductor at or near the terminal.
Crimp terminals shall be used on all wiring operating at 64 volts or higher.
In general, connections shall be made by means of terminal blocks.
Only ring tongue terminals are acceptable unless specifically approved by DTC. The
use of spade type and "Fast-on" terminals shall be prohibited.


Issue Date: 3/28/05                     3-13
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


Solder connections shall not be permitted on Linear Induction motor cables and
connections.
Solder connections shall be permitted on printed circuit boards.

3.26.6     Terminal, Tool, and Die Manufacturer

Mechanical or compression type connectors and terminals shall be AMP standard
connectors and terminals. Tools and any associated dies shall be of AMP manufacture.
Installation shall be by AMP tools that do not release until the crimping process is
completed.

3.27     WIRE MARKING

Wire markers shall be consistent in quality and form with existing wire markers. Missing,
damaged or illegible wire markers shall be renewed.
All wires, terminal studs, connections points and connectors shall be plainly and suitably
marked with permanent type markings as per APTA RP-E-002-98, section 5.13, so that
circuits may be easily identified, and these markings shall conform to a standard wire
numbering system approved by DTC.
Except for spares and wires entirely within an equipment enclosure, each wire of gage
AWG No. 8 and smaller shall be permanently and legibly marked along its entire length.
Wires of gage larger than AWG No. 8 may have wire markers applied at each end of the
wire.
Spare wires and wiring entirely within an equipment enclosure may have a single wire
marker at each end, subject to acceptance by DTC in lieu of continuous marking.
Wires shall be marked by laser etching of the sleeve. As an alternate, markers may be
of the printed, heat-shrinkable type.
Hand printing is prohibited.
Markings shall be non-conductive.
Marking material/ink shall not be adversely affected by normal electrical cleaners and
solvents.
Marking material/ink shall be UV protected to withstand exposure to the elements
without discoloration.
Wire markings shall be provided every 8 inches.

3.28     CONDUIT

Existing conduit requiring renewal or reconfiguration shall be of similar composition as
that removed.




Issue Date: 3/28/05                    3-14
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


All conduit couplings shall be of an ANSI approved type. Conduit installed on the trucks
or in under floor areas over the trucks shall be standard weight, galvanized steel with
threaded fittings. All conduit ends shall be deburred inside and out to remove sharp
edges and all pieces shall be blown out with compressed air and cleaned before
installation to remove filings and other foreign material.
Rigid aluminum conduit shall consist of seamless, rigid aluminum alloy conforming to
ANSI C-80.5 and to the requirements of Standard UL-6. All threads shall be covered
with an oxidation-inhibiting compound. Aluminum fittings shall be used to assemble
aluminum conduit and shall be made to the same grade and alloy as the conduit.
Steel conduit shall be mild steel in standard lengths with threaded ends and hot-dipped
zinc-coated exterior and interior surfaces. It shall be free of burrs and projections,
circular in cross-section, of uniform wall thickness and shall conform to the requirements
of ANSI Standard 80.1. The threads per inch and length of threading shall conform to
ANSI Standard B-2.1 on Pipe Threads.
Steel fittings shall be used to assemble steel conduit. Elbows, nipples, and couplings
shall be made of the same grade of steel as that employed in the conduit. All fittings
shall be treated, coated, and threaded according to the requirements for zinc-coated,
rigid steel conduit and shall conform to Underwriters Laboratory Standard UL-6.
Flexible conduit shall be an ANSI approved type and shall be of the highest grade and
quality. It shall be watertight, interlocking steel strip-protected, with an approved rust
resistive coating.
Conduit shall be sized such that the sum of the cross-sectional areas of the conductors
and their insulation does not exceed 40% of the cross-sectional area of the conduit for 3
or more conductors. For 2 conductors, a limit of 31% shall be used, while for a single
conductor a limit of 53% will be permitted. For conduits having a length not exceeding
24 inches without bends of more than 15 degrees between enclosures, a maximum fill
of 60% shall be permitted.
A run of conduit between junction boxes and/or pulling outlets shall not contain more
than the equivalent of four quarter bends (360 degrees total) including the outlet fittings.
Bend radii at the inner surface of the bend shall be no less than 8 times the nominal
inside diameter of the conduit.
All conduit bends and offsets used shall be made by the use of special forms or tools
and shall have the largest radius possible so that wires can be drawn (in and out)
without the use of tackle or power.
Conduits shall be securely clamped with all runs electrically grounded to make a
continuous ground. Suitable insulation shall be provided to prevent electrolysis where
aluminum may come in contact with other metals.
All conduits shall be arranged to prevent moisture traps and shall drain toward control
boxes, except that all open-ended conduits shall be installed in a manner to ensure
gravity drainage of moisture out of the end. The conduit arrangement and installation
shall be subject to DTC review and approval.



Issue Date: 3/28/05                     3-15
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


The conduit fittings and junction boxes for passenger car wiring shall be as
manufactured by the Contractor or by a supplier of a comprehensive line of parts. The
Contractor shall submit the proposed product line for DTC approval. All conduit fittings
and junction boxes shall be provided with gaskets.
All exterior junction boxes shall be fabricated of steel with a minimum wall thickness of
14 gauge. All exterior junction boxes shall be waterproof and shall be connected in such
a way that drainage from equipment groups shall not pass through the conduit into the
junction boxes. Interiors of all junction boxes shall be primed and then protected with a
white, insulating epoxy powder coating.
The open ends of conduits shall be provided with strain relief type fittings with extended
rubber bushings, bell-mouth fittings or insulated throat box connections. All conduit
entries into removable equipment boxes shall be made through watertight access
panels secured by captive screw fasteners.
All junction box covers shall be secured with compressive spring-type latches or captive
screws. All fasteners used in junction boxes shall be stainless steel. All covers shall be
designed to accept or mate with a bulb-type clamp-on seal.

3.29     ELECTRICAL DEVICES AND HARDWARE

In addition to the requirements specified elsewhere in this document, each contactor,
relay and switch shall be as follows:
Designed to meet of exceed current industry standards for railroad applications.
Be fully accessible for inspection, repair-in-place and replacement.
Have a maximum of two (2) wire terminations on any one low voltage contact of the
device.
Contact tips shall not be placed in parallel for the purpose of carrying a current load at
or above the manufacturer’s tip rating.
Electrical connections shall be captive screw or nut and bolted together with crimp-on /
cable terminals.
Screw held compression terminals shall not be utilized.
If it is necessary to electrically parallel SCRs or diodes, the paralleled combination shall
contain equalizing circuits to ensure current sharing.
Where a component failure may result in additional component failures, each such
component shall be fused or suitable protected.
Each failure shall be in a direction that places neither passengers, the crew, bystanders,
nor the equipment in jeopardy.

3.29.1     Contactors and Relays

All contactors and relays shall be service proven devices used in railroad applications.



Issue Date: 3/28/05                     3-16
IFB 4-002 TECHNICAL SPECIFICATION                  3 - MATERIALS AND WORKMANSHIP


Devices shall be constructed in a very heavy-duty fashion suitable for use in railroad
service.
The coils of all devices shall be suppressed using an RC-network or solid state devices
appropriately sized to protect against transients generated along the low voltage
network.
Contact tip rating shall be stated for the worst condition of reduced surface contact
which may result from tip misalignment during normal operation of the device.
The contactor installation shall be such that the arc spray is directed by an arc chute
away from ground and any other electrical devices proximate to the contactor.
The estimated lifespan of all contact tips shall not be less than 4 years.
All contactors shall be constructed so that the main contact tips make and break with a
motion (wipe) that prevents deposits or pitting.
All contactors shall be built with series-fed blowout coils.
The Contractor shall demonstrate the ability of each contactor type to reliably interrupt
current over the full design operating range.
All devices shall be readily identifiable by means of a permanent, durable marking strip
giving the device circuit designation.
No identifications shall be obscured, or partially obscured, by wiring routing.
The identification strip shall be mounted adjacent to the mounting point of the device.
Bifurcated contacts shall be used in low voltage applications, whenever necessary due
to dry contacts or low current switching arrangements.
All time delay relays shall be of the R-C delay or solid-state type.
Pneumatic or mechanical time delay devices shall not be permitted.
Plug-in relays shall be positively retained by means of a restraining clip or bar. The
retaining device shall be captive, rugged constructed and shall be easily positioned for
relay installation or removal without the need for special tools. When plug-in relays are
removed, the retainer shall be retained so that it cannot come in contact with devices
which may have exposed energized electrical circuits, and shall not interfere with the
operation of any other device when in this position.

3.29.2     Switches

Switches shall be provided with a “keying” feature such that after installation, the body
of the switch will be constrained from rotation.
Non-rotary switches shall be mounted in a vertical position with the “up” position being
“on”. No secondary mechanical means shall be utilized to achieve this.




Issue Date: 3/28/05                      3-17
IFB 4-002 TECHNICAL SPECIFICATION                  3 - MATERIALS AND WORKMANSHIP


3.29.3     Circuit Breakers

All circuit breakers provided shall be extremely rugged and fully suitable for the service
intended.
They shall be of the highest quality procurable.
All circuit breakers of the same rating shall be of the same manufacturer and model,
throughout the vehicle.
The “on”, “off” and “tripped” positions of all circuit breakers shall be permanently marked
on the handle, or prominently on the case, of the circuit breaker.
The circuit breaker, when tripped, shall assume a distinct position between the “on” and
“off” positions to permit determination of the fact that it has been tripped by either its
overcurrent or shunt trip elements.
Circuit breaker handles shall protrude from the circuit breaker panel covers sufficiently
to be operational in all positions.
Circuit breakers shall be individually renewable without disconnecting or removing
anything other than the mounting fasteners and electrical connections of the breaker to
be renewed.
Electrical connections to circuit breakers shall either be threaded to accept machine
screws or use threaded stud.
Wires to circuit breaker studs shall use ring terminals.
Circuit breaker terminals shall not be used as junction points.
Each and every power circuit shall be protected by an individual circuit breaker.
No circuit breaker shall protect more than one circuit, nor shall any one circuit be
protected by more than one circuit breaker.
All circuit breakers shall be sized by current rating and tripping time to protect both the
associated equipment and the minimum size wire for power distribution within the
protected circuit without causing nuisance tripping.
High voltage circuit breaker poles may be connected in series if necessary to achieve
the stated voltage interruption requirements.
Each circuit breaker pole shall be equipped with adequate means of arc extinction to
prevent flashover.
Circuit breaker current rating shall be clearly and permanently marked and shall be
completely visible after installation.
Electrically operating circuit breakers shall be arranged for operation from the low
voltage DC trainline power.
All circuits operated above 125Vac shall be considered high voltage.
AC circuit breakers shall match the interruption capacity to the source.



Issue Date: 3/28/05                     3-18
IFB 4-002 TECHNICAL SPECIFICATION                   3 - MATERIALS AND WORKMANSHIP


Each low voltage circuit breaker shall be either one or two pole devices depending upon
the intended function.
All high voltage circuit breakers shall be devices with not less than three poles
connected in series.
The Contractor shall submit a comprehensive list of suggested fuses and circuit
breakers for DTC review and acceptance.
Circuit breakers shall not be used to perform the functions of a switch.
The use of circuit breakers shall be minimized.
Ratings for circuit breakers shall be minimized and vice-versa.

3.29.4     Fuses

Fuses shall be used only where specified, or where the use of a circuit breaker is not
technically feasible.
Each fuse shall be permanently identified and readily accessible.
The rating of each fuse shall be clearly and permanently marked on the fuse and holder.
The fuse holder shall have fuse retention devices at both ends.
Air gap and creepage distances shall be suitable for the application.
Each fuse compartment shall have a spare fuse of identical size and rating as the “in-
circuit” fuse.
The spare fuse shall be mounted in a convenient location and marked “spare”.
Blown fuse indication shall be provided.

3.29.5     Bus Bars

Bus bars shall be fabricated from UNS number C10100, C10200, or C11000 copper,
conforming to ASTM B187 as necessary.
Current densities, other than at joints, shall not exceed 2000 amperes per square inch,
and in any case shall not exceed a value which would cause a bus bar temperature rise
greater than 40 degrees C above ambient.
Current densities in joints shall not exceed 150 amperes per square inch.
Bus bar joints shall be silver or electro-tin plated.
Bus bar shall be properly brazed together at joints, unless bolted connections are found
to be absolutely necessary for maintenance purposes, and are specifically accepted by
DTC.
The overlap at bus bar joints shall be no less than ten (10) times the thickness of the
bus material.
Bus bar connection bolts shall be torqued to obtain a uniform bus bar connection
pressure of 200 PSI.

Issue Date: 3/28/05                       3-19
IFB 4-002 TECHNICAL SPECIFICATION                   3 - MATERIALS AND WORKMANSHIP


Bolting hardware shall be plated steel with Belleville washers to maintain connection
pressure.
Except for connection areas, bus bars shall be safety-insulated, using a high-dielectric,
powder coating or accepted means.
Tape is not acceptable.
Bus bars that are behind insulation panels are exempt from this requirement.

3.29.6     Capacitors and Resistors

Hermetically sealed, dry tantalum capacitors, in metal cases, shall be used in place of
aluminum electrolytics, except for very high values which are not commercially practical
or available, in which case long life grade aluminum electrolytics shall be used.
Commutating capacitors shall be a paper or plastic film type, shall incorporate a non-
toxic impregnant, and shall be chosen to give a service life of at least twenty (20) years.
Filter capacitors shall have high ripple current rating for long life.
Capacitors shall be derated 20% for voltage based on nominal supply voltage and
maximum case temperature.
If filter capacitors are exposed to low ripple voltages, lesser filter values of derating may
be accepted if it can be shown that reduced operating temperatures can be achieved
due to lower dissipation; however, the sum of the dc and ac ripple voltages shall always
be less than the capacitor’s voltage rating at a maximum case temperature of 85
degrees C.
Except for braking power resistors, all resistors shall be derated 50% for power
dissipation.
Other power resistor applications may be submitted for acceptance of lower derating, on
a case-by-case basis.
Fixed value type resistors shall be provided.
Calibration shall not require adjustable resistor or trimming potentiometers unless
absolutely necessary.

3.29.7     Switch, Circuit Breaker, and Fuse Panels

All switch, circuit breaker and fuse panels shall be dead front types mounted in specified
equipment enclosures.
Each switch and circuit breaker panel shall carry the necessary apparatus, arranged to
be easily accessible for connections and designed to prevent operating or maintenance
personnel from coming in contact with live parts when operating the switches or circuit
breakers.
All live portions of the protected circuitry shall be completely concealed so that no
danger of electrocution or shock exists from the touching of the panel or any
appurtenances or devices mounted thereto.


Issue Date: 3/28/05                       3-20
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


All switches, circuit breakers, fuses, and indicating lights shall be provided with a
nameplate of raised or recessed lettering on the “dead front”, clearly identifying the
circuit which each controls and its circuit designation.
The “dead front” panel shall conform to NEPA No. 7d, Article 384.
The “dead fronts” shall be made of moisture-proof, electrically insulating, laminated
phenolic or fiberglass, of accepted quality suitable for switchboards. Asbestos shall not
be used.
A wiring gutter shall be provided along the top, sides, and bottom, for the routing of high
voltage leads to their designated circuit breakers.
The panel shall be secured by accepted, captive fasteners and shall be configured for
each removal so maintenance and repair action is not impeded.
Power distribution to the switches and circuit breakers shall be from a bus bar or bus
circuit.
Distributing power by successive or “daisy-chained” connections between device
terminals will not be permitted.

3.29.8     Illuminated Status Indicators and Annunciators

All illuminated status indicators, annunciators or similar devices shall be long-life Light
Emitting Diode (LED) type lamps, rather than incandescent bulbs.

3.29.9     Rotating Equipment

Rotating machinery shall be suitable for continuous duty, and the continuous duty shall
be confirmed in accordance with IEEE Standard No. 11.

3.30     WIRING

All wiring and cables shall be in accordance with AAR RP-585 and the
recommendations of APTA RP-E-009-98 section 6.0 (or latest version).
New wire and cable shall be soft annealed copper, tinned, stranded, and jacketed with
radiation cross linked polyolefin (Exane), or Engineer accepted equal, in accordance
with AAR Standard S-501.
The Contractor and each manufacturer of equipment shall submit a sample along with
the specifications of each wire size for acceptance by DTC prior to commencement of
production.
All wiring shall be printed with the manufacturer’s identification, conductor size, voltage
rating and temperature rating.




Issue Date: 3/28/05                     3-21
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


3.30.1     Conductor Size

Wires for control and auxiliary circuits shall not be smaller than AWG No. 12, except
that smaller wire, where adequate, and subject to prior acceptance by DTC, may be
permitted for wiring within auxiliary control units and electronics units.
When multi-conductor cables are needed, wire sizes smaller than AWG No. 12 may be
used provided that the size selected is satisfactory for the electric load and function this
wire is expected to perform. Current rating shall be determined per the
recommendations of APTA RP-E-009-98 (or latest version) and the NEC.
Control and Communication Train Lines shall be sized for car operation in a two (2) car
consist.

3.30.2     Wire Sizes and Types

A minimum number of different wire types and sizes shall be used in wiring the car.

3.30.3     Heater Connections

High temperature silicone insulated wire, in accordance with AAR Standard S-503
(former No. 590), shall be used for connections to heaters, and for interconnection of
heater elements and units.

3.30.4     Headlight and Resistor Connections

Wire shall be silicone insulated per AAR Standard S-503 (former No. 590).

3.30.5     Aluminum Wire and Cable

The use of aluminum wire and/or cable is specifically prohibited.

3.30.6     Other Guidelines

Where practical, standardized prefabricated wiring harness with quick-disconnect
connectors shall be utilized. Standard harnesses that shall include spare wires. This
shall exclude wiring to underseat heaters.
Each wire harness between equipment locations shall contain a minimum of ten (10)
percent spares
All circuits and branches must be separable to isolate when searching for shorts.
High and low voltage wiring and cabling shall be physically separated.
When some parts of a given piece of electrical apparatus are to be connected to two
different nominal voltages, all wiring thereto shall be insulated for the higher voltage.
All wire lengths shall include a service loop, which allows for three (3) re-terminations of
the wire.



Issue Date: 3/28/05                     3-22
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


The vehicle wiring shall meet all the above requirements and all recommendation of
APTA RP-E-002-98 (latest version).

3.30.7     Application and Installation of Wire

Car wiring methods and materials shall be in accordance with Chapter 3 of the National
Fire Protection Association's Publication, NFPA No. 70 (NECS) current issue, except
where otherwise required by the Specification, or where permission has been granted
by DTC, and with the exception that all wire shall be stranded.
All wiring shall be performed by or under the direction of a qualified and experienced
wireman.
The wireman shall be provided with appropriate tools for skinning insulation, cutting,
tinning, soldering, and attaching mechanical or compression type terminals to the
conductors.
The tools for mechanical and compression type connections must be produced by a
single manufacturer.
Care must be taken in removing insulation from the conductor to avoid nicking of the
wire or strands of the conductor cable.
Wire in ducts and conduit shall be free of kinks and insulation abrasions and insulation
skinning.
The layout of wiring shall be designed in advance of its installation and in cooperation
with those furnishing the related equipment.
Insofar as practicable, all wiring shall be fabricated on the bench into convenient units
and installed in prefabricated groupings and standardized locations.
Grounding connections shall be brazed and bolted, or welded and bolted to, or silver
soldered and bolted to, the car body steel.
Wiring for communication systems shall be done in an accepted manner to conform with
the requirements established by the manufacturer of such apparatus.
Conductors of AC and DC current shall be separated by a physical barrier, to be
accepted by DTC.

3.30.8     Undercar and Overhead Wiring

Except as noted below, all wiring shall be run in EMT thin wall steel or heavy wall
aluminum conduit.
Sufficient pull boxes shall be provided in long conduit runs to facilitate future repair and
maintenance in locations acceptable to DTC.
The interior of all conduit and fittings shall be carefully finished to eliminate cutting of
insulation.




Issue Date: 3/28/05                     3-23
IFB 4-002 TECHNICAL SPECIFICATION                  3 - MATERIALS AND WORKMANSHIP


Where necessary to facilitate component removal and replacement at ends of conduit
runs to removable panels or terminal strips, minimum lengths of flexible liquid tight
conduit may be provided.
Conduit fittings, receptacles, wiring devices and junction boxes for car wiring shall be as
manufactured by the Thomas and Betts Company, AMP, Appleton, Crouse-Hinds,
Hoffman, Pyle National, or accepted equal.
All covers for undercar fittings, and boxes, shall be gasketed using DTC approved
materials and shall meet all emissions and toxicity criteria.
Interiors of boxes shall be suitably protected by insulating paint against condensation
and corrosion.
When more that one supplier is used, all fittings which require covers and are of the
same size shall be supplied by the same manufacturer, or shall be interchangeable.
Power cables shall be twisted between supports in order to cancel undesirable fields.
Power train line cables shall be supported by neoprene cable cleats on the underside of
the car structure with sufficient spacing between individual conductors to permit
adequate ventilation.
Insulated bushings shall be used in all conduit and condulet fittings.
Wire harness may be covered with silicone glass cloth tubing and secured to wire
supports with cable ties.
These wire harnesses may be used only in the ceiling and locker areas.
In addition to the above requirements, undercar and overhead wire and installation shall
meet all recommendations of APTA RP-E-002-98 (or latest version).

3.31     ELECTRONICS

3.31.1      Semiconductors

The Contractor shall be responsible for insuring that all electrical and electronic circuitry,
whether of his own design and manufacture or of those of his Manufacturers and
Suppliers, shall meet as a minimum the criteria listed in this section with regard to the
use of semiconductors.
Semiconductors for electronic circuits shall be adequately rated, including current rating,
power rating, and PIV rating and performance characteristics for the application
intended.
Each discrete semiconductor shall have the following minimum voltage breakdown
rating:
   •     Transistors, thyristors, GTO and IGBT electronic power components operated
         from the nominal battery supply, or those connected to trainlines, shall have
         minimum breakdown ratings of four (4) times the maximum circuit voltage.
         Suppression devices shall be provided as necessary to protect the device and
         limit the circuit voltage.

Issue Date: 3/28/05                      3-24
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


   •   Diodes operated from the nominal battery supply used as suppression devices,
       or those connected to trainlines, shall have a minimum breakdown rating (PIV) of
       1000 volts.
   •   All discrete semiconductors operated from inverters or other isolating devices
       shall have a minimum breakdown rating of two (2) times the maximum circuit
       voltage, except where specifically detailed otherwise. Suppression devices shall
       be provided as necessary to protect the device and limit the circuit voltage.
All semiconductors shall be operated at less than 50 percent of the maximum
continuous current rating, or 50 percent of the maximum continuous power rating, which
the more restrictive rating being the controlling value.
Circuits shall be designed to limit excessive current to semi-conductors, to prevent
damage from high discharges (spikes) and to limit excessive temperature through
property designed heart sinks, where required.
Semiconductors shall be positively ventilated by the clean air system and located to
allow easy replacement.
Ventilation for cooling shall not pass ambient air over areas of voltage stress.
Integrated circuits operated from the battery supply through inverter or other isolated
devices shall be operated within the voltage and current ratings specified by the
manufacturer, derated to less then 50 percent of the maximum stress level at the
maximum operating temperature of the device, as specified by the manufacturer.
Where the supply to integrated circuits is regulated and surge protected, the voltage
rating shall be 15 percent below the manufacturer’s recommended maximum.
In addition, the maximum power shall be limited to 50 percent of the manufacturer’s
specified maximum at the maximum operating temperature.
All semiconductors shall be rated for operation over the temperature range of –40
degrees C to 85 degrees C.
All discrete semiconductors devices, such as diodes, tyristors, and transistors, shall be
standard devices available from at least two (2) different U.S. manufacturers.
Non-jedec registered devices which carry more than 10 amps may be used, provided
the Contractor has obtained prior Engineer acceptance.
All integrated circuits shall be burned in and screened for defects to a level equivalent to
ML-STD-883, method 5004, reliability class B.
The method used must be submitted to DTC for acceptance.
Alternate methods based on a minimum 100 hour burn-in for the completed assembly
will be considered.
The burn-in shall be performed with the equipment operational (power on), with the
necessary input signals and loads to simulate the maximum power dissipating
conditions in the device, and with functional monitoring to identify intermittent
malfunctions.


Issue Date: 3/28/05                     3-25
IFB 4-002 TECHNICAL SPECIFICATION                 3 - MATERIALS AND WORKMANSHIP


Matching of components is permitted only if the components are normally available from
the manufacturer in matched sets.
Germanium semiconductors shall not be utilized.

3.31.2     Printed Circuit Boards

Printed circuit boards shall be designed, constructed and inspected to MIL-STD-275,
latest revision, or Engineer accepted equal unless more stringent requirements are
noted herein.
Traces shall be made as wide as practical, with the minimum width being based on a 10
degree C temperature rise.
The component side of the board shall be printed with the component reference
designation and such other information as may be required to repair and troubleshoot
the board, such as capacitor polarity and at least two (2) leads of each transistor and
thyristor leads.
Each Integrated circuit shall have an index mark on the component side of the board,
visible with the component inserted, to indicate proper keying and insertion.
Components shall be fastened to the board in such a manner as to withstand repeated
exposure to shock and vibration.
Sufficient clearance shall be provided between components to allow testing and
replacement without difficulty.
All exposed components, except socked integrated circuits, shall be coated with
conformal insulating and protective coating conforming to MIL-1-46058.
The classification of the coating shall be subject to the review and acceptance of DTC.
Provision shall be made on each printed circuit board for “keying” to prevent insertion
into the wrong socket.
Circuit boards in safety related systems and subsystems shall be interlocked through a
safety circuit to disable the vehicle if a circuit board is removed.
Printed circuit board connectors shall conform to MIL-C55302 or Engineer accepted
equal and shall have plated contacts as required to support a minimum of 500 insertions
and removals without increase in contact resistance.
Wire wrap connections shall not be used unless specifically accepted by DTC.
Test jacks shall be provided in appropriate locations on modules and printed circuit
boards in sufficient quantity to localize fault isolation to the lowest replaceable assembly
(e.g. PC board, input, wiring grounds).
A negative return test point shall be provided.
Each test point shall accept and hold a standard 0.080 in. diameter tip plug and shall be
identified by appropriate markings.




Issue Date: 3/28/05                     3-26
IFB 4-002 TECHNICAL SPECIFICATION                 3 - MATERIALS AND WORKMANSHIP


Printed circuit boards and modules shall be positively retained by means of keeper bars
or similar means.
Keeper bars shall be retained by chains or links to prevent loss when removed to allow
change-out of circuit boards. The use of tools to remove or replace the keeper bars
shall not be required.
Except for ICs, plug-in components shall be retained with a retaining device.
The use of multi-layer PC boards shall be submitted for review and acceptance by DTC.
All printed circuit boards with the same function shall be interchangeable between
equipment groups without additional adjustment.
Circuit boards shall be designed to eliminate susceptibility to electrostatic discharge.
Surface mounted technology shall be permitted in applications, subject to the review of
DTC.
The use of jumper wires shall be minimized and shall not be used without the prior DTC
acceptance.
Mounting arrangement of components on printed circuit boards is subject to DTC
approval.
Large components shall be supported in addition to solder connections.
Power resistors shall be mounted on standoffs so that the resistor bodies do not contact
the board, spaced far enough away from the board so that heat from the resistor shall
not discolor or damage the board.
Components shall be fastened to the board in such a manner as to withstand repeated
exposure to shock and vibration.

3.32     SOFTWARE AND MICROPROCESSOR BASED SYSTEMS

3.32.1     General

All computer hardware and software provided under this Contract, whether resident
within a microprocessor-controlled intelligent subsystem, provided as part of test or
interface equipment, provided for the purpose of post-download data analysis and
processing, or incorporated within training technology, shall be subject to the
requirements provided in this Section.
Hardware and software requirements depend on the degree to which the hardware
and/or software is custom designed for or applied to this project.
“Commercially Available” hardware or software is defined as being readily available in
the United States through retail and wholesale sources and shall be subject to the
applicable documentation and training requirements of this section.
“Non-commercially available” hardware or software is defined as being developed or
modified according to the requirements in this Specification, and shall comply with all of
the design, documentation and training requirements of this Section.


Issue Date: 3/28/05                     3-27
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


All hardware and software used to control or monitor safety functions shall comply with
the requirements of 49CFR238.105, and the Contractor shall prepare and submit to
DTC a Hardware and Software Safety Program as defined in that section.
All references to industry standards shall be taken to refer to the latest editions at the
time of this contract’s Notice-to-Proceed.
All suppliers, including the Contractor, who will be providing processor-based products
shall have a mature software development process.
The suppliers’ software development process, including proprietary or internal
procedures, shall be available for inspection and/or review by DTC.

3.32.2     Design Process

The Contractor shall utilize a Software Quality Assurance Plan in accordance with
ANSI/IEEE Standard 730, which shall describe a mechanism for orderly software
development using the applicable documents listed in the Software Documentation
portion of this Section. Software QA, design process and documentation shall be fully
integrated with the corresponding hardware process.
Software shall be reviewed as an integral part of each applicable design review. The
correlation between design reviews and software submittals shall be as shown in the
table below.
Software QA shall be part of all applicable QA audits or inspections. Software revision
control shall be treated the same way as drawing revision control.
Software validation (testing) shall be part of the total project testing process. Test
procedures, testing and test reports shall be subject to the review, witnessing and
documentation process required by this Specification. Software testing shall be a
prerequisite to higher level testing, such as system level and vehicle level tests.
In addition to the requirements of this section, any software, firmware, processing
device or computer providing a safety-critical function shall comply with applicable
Software Safety requirements of Section T25 “Safety”.




Issue Date: 3/28/05                    3-28
IFB 4-002 TECHNICAL SPECIFICATION                 3 - MATERIALS AND WORKMANSHIP




       Review Type                   Software Related Documentation
       Concept Review                Software QA Plan
                                     Software Configuration Management Plan (SCMP)
                                     Preliminary System Functional Description
                                     Preliminary Software Requirements Specification (SRS)
                                     Identification of languages, compilers, CASE tools and
                                     operating systems to be used
                                     Identification of degree of software transportability


       Preliminary          Design System Functional Description
       Review                        Software Requirements Specification (SRS)
                                     Preliminary Software Design Description (SDD)
                                     Preliminary SVVP


       Critical Design Review        Updated System Functional Description
                                     Updated Software Requirements Specification (SRS)
                                     Software Design Description (SDD)
                                     Final SVVP


       Test    Procedures       and Detailed Test Procedures, Interim SVVR’s at completion
       Testing                      of each development phase and final SVVR.

3.33     SOFTWARE SYSTEMS FUNCTIONS AND FEATURES

3.33.1     Hardware Platform

Carborne and custom computer hardware shall be designed and constructed in
accordance with all applicable general electronic design principles of this specification.
Any computers, whether portable or not, and any microprocessor hardware shall be
readily available through retail and/or wholesale outlets in the U.S. for 15 years and
shall be from accepted domestic manufacturers. If they are not available for 15 years,
they shall be supported with replacement parts or be capable of being replaced with
direct compatible replacements.




Issue Date: 3/28/05                      3-29
IFB 4-002 TECHNICAL SPECIFICATION                  3 - MATERIALS AND WORKMANSHIP


The hardware, software, data repository and firmware delivered or developed under this
Contract shall be able to process data (including, but not limited to, calculating,
comparing, and sequencing) from, into, and between all dates, including leap year and
daylight savings time calculations. In other words, programming shall not be based on
an artificial start or end date. The date data processing shall not experience abnormal
ending and/or invalid or incorrect results from the hardware, software, data repository or
firmware in operation of the business of DTC. Each hardware, software, data repository
or firmware’s date data interface shall support a four-digit year format.
All microprocessor-based systems shall be based on an established family of
microprocessors in wide use in the control system industry and the rail industry. They
shall be supported by a full range of software development languages and diagnostic
programs similar to that available for the Intel and Motorola family of devices.
Any use of commercially-available computer boards must be specifically accepted by
DTC on a case-by-case basis. Such acceptance will be based upon a technical review
of the product, product documentation, and a commercial assessment of product
availability.
The computer shall be powered by dedicated, transformer-isolated power supplies
driven from the 64 VDC local bus, if carborne.
The computer shall incorporate a means, without the use of a battery, to maintain
microprocessor control in the event of a 250 ms interruption in supply power.
All processor system input and output signals shall be through isolation buffers. High
voltage inputs and outputs shall be isolated external to the microcomputer card rack.
Low voltage (battery and logic voltage level) inputs and outputs shall be isolated via
buffer cards in or external to the microcomputer card rack. The isolation buffers shall
accomplish the following:
       1.      Protect and isolate the system from damage due to over-voltage, under-
               voltage, transients, shorts, and open circuits.
       2.      Perform necessary voltage translations.
       3.      Remove noise and undesired signals.
       4.      Pre-processing shall limit, discriminate and format those signals that
               would otherwise require excessive processor time.
       5.      Isolation buffers shall consist of optical isolators, transformer isolators, and
               other circuits appropriate to the application.
       6.      Program code and fixed data shall be stored in the most appropriate form
               of PROM available at the time of vehicle production.
       7.      Any EPROM windows shall be covered with labels that are opaque at the
               UV erasing wavelengths.
       8.      Flash PROM circuitry shall be configured so that reprogramming can be
               disabled via a semi-permanent hardware mechanism.



Issue Date: 3/28/05                       3-30
IFB 4-002 TECHNICAL SPECIFICATION                  3 - MATERIALS AND WORKMANSHIP


       9.      Use of an extender board for programming is an example of an acceptable
               solution.
       10.     Software upgrades shall be performed using a password protected
               function on the PIU. This requirement is not applicable to systems that
               are not re-programmable by PIU.
       11.     To minimize the number of individual batteries that will need to be
               maintained, the use of battery backup shall be limited to the extent
               practical, and shall be subject to DTC’s acceptance. Where permitted,
               backup or standby batteries shall meet the following requirements
       12.     Rechargeable batteries shall be sized to retain data for at least six months
               without charging, and shall be located such that leakage cannot damage
               any control system components.
       13.     Battery life shall be no less than five years, regardless of type.
       14.     Systems using standby or backup batteries shall annunciate the need for
               battery replacement.
       15.     Batteries shall not be connected by soldering.
       16.     Necessary RAM control data shall not depend on battery back-up, but
               shall be stored in non-volatile memory and “shadowed” to RAM for use.
       17.     The hardware shall be designed to allow program expansion without
               hardware modification. Expandability and capacity requirements are as
               follows:
               a.     The memory needs of the installed software shall not utilize more
                      than 50% of the installed memory capacity. This requirement
                      applies individually to each type of memory installed, whether it be
                      EPROM, EEPROM, Flash PROM, RAM, or other type.
               b.     Peak processing time demands shall not be greater than 50% of
                      the available processor capacity, except as indicated below. The
                      Contractor may petition for relief from the 50% requirement, based
                      on product maturity and the lack of potential for expansion or
                      modification. In no case may more than 75% of the peak processor
                      capacity be utilized and, generally, more margin will be required.
               c.     Simple singular functions performed by dedicated embedded
                      processors may utilize up to 75% of the available processor
                      capacity and do not have to provide spare I/O capability.
               d.     The hardware shall include spare input and output channels of
                      each type used within the system, except for major output drivers
                      where the quantity is fixed by the overall system design (e.g.,
                      traction motor semi-conductors and sign character drivers). In
                      addition, the architecture and assembly construction shall allow for
                      the installation of additional I/O hardware.



Issue Date: 3/28/05                      3-31
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


3.33.2     Operating Systems, Languages and Compilers

Software may be written in a high or low level language; however, high-level languages
such as C/C++, Pascal, etc., are preferred. The language, and its implementation for
the selected microprocessor system, shall be commercially available in English.
All languages and operating systems must have an acceptable customer base
(widespread use), and be accepted by DTC. All operating systems, including those of
PIUs and other test equipment, shall be able to communicate in a common language.
Compilers shall be commercially available. Proprietary compilers shall not be used.

3.33.3     General Features

Software shall perform the following basic functions:
Implement the desired control scheme such that the specified performance is achieved.
Monitor all inputs for unsafe, erroneous, or unknown conditions or combinations of
conditions.
Sample all input conditions at rates sufficient to detect and remedy all unsafe or
damaging conditions in the shortest possible time. Sampling rates and program
execution times shall be such that the control system is not the limiting factor in
response to unsafe or damaging conditions. All software shall be designed to ensure
that the timing requirements for safety-related tasks are always met.
Limit all output commands to safe levels regardless of any combination of input
conditions.
Perform self-diagnostic routines and respond promptly, safely, and predictably to
detected faults. The self-diagnostics shall include tests for program corruption and
integrity in read/write memories such as EEPROM and flash PROM.
Respond safely and predictably when powering up or recovering from power
interruptions. All power interruptions likely to have corrupted temporary storage shall be
detected and cause the system to re-initialize all affected routines and temporary data.
Detection of power interruptions may be by hardware.
Permit thorough interrogation of all input, output, and internal conditions by internal,
system level, vehicle level and external diagnostic equipment.
Software version numbers shall be included within the firmware code and shall be
accessible to the System and Vehicle Level Diagnostic Systems.
Multi-chip programs must self-test during initialization to assure that the correct
complement of chips is installed.
Processor system parameters shall be adjustable during commissioning via PIU. During
design review, appropriate parameters shall be suggested by suppliers for acceptance
by DTC.




Issue Date: 3/28/05                    3-32
IFB 4-002 TECHNICAL SPECIFICATION               3 - MATERIALS AND WORKMANSHIP


3.33.4     Testability

All features and functions of software systems shall be testable on a systems level in
the field, using portable test equipment and procedures provided under this contract.
Specific acceptance by DTC is required for any feature that is not testable on a systems
level.
For features that are only testable off the car with special equipment, all such equipment
shall be supplied by the Contractor as test equipment, and become the property of
Authority. This equipment shall provide the logic, sequencing, and emulation necessary
to verify that the software functions as intended. In lieu of separate equipment,
appropriate test functions may be provided within the PIU.
Type tests of all processor systems shall verify the proper operation of all software
features, including diagnostics. Such testing shall be performed any time the software
is changed prior to putting it into service.

3.34     SOFTWARE DOCUMENTATION

For non-commercially available software, thorough and accurate software
documentation, including source code, documented by ATA 102, shall be submitted by
the contractor to DTC for review and acceptance. The Contractor shall provide
sufficient documentation to permit DTC to fully comprehend and analyze the operation
of the equipment in which the software is to be installed; and to enable DTC to maintain
and modify the software to correct problems, adapt it to changing requirements, add
features, and port it to a new hardware platform.
The Contractor shall define a single software documentation methodology for the
project and require all subcontractors to comply with it. The methodology shall be
submitted to DTC for review and acceptance. If Computer Aided Software Engineering
(CASE) tools are used which automatically generate documentation, they shall be
consistent with the Contractor’s documentation methodology. The Contractor shall
provide descriptions to enable DTC design reviewers to understand the documentation
methodology. Software documentation training for specialized CASE tools shall be
included within the formal Training Program.
Documentation for non-commercially available software shall be divided into two
categories, Category A and B. Classification of software as Category A or B shall be
subject to DTC’s acceptance. In any case, Category B software must be of an existing,
service-proven design. Newly-developed software that is intended for use on other
applications as well shall be considered as Category A regardless of the Supplier’s
intended use of the software in the future.




Issue Date: 3/28/05                    3-33
IFB 4-002 TECHNICAL SPECIFICATION                 3 - MATERIALS AND WORKMANSHIP


         Category A:
         Application-specific software, developed or adapted specifically for this Contract.
         Newly-developed software intended for use on other applications as well shall be
         considered as Category A regardless of the Supplier’s intended use of the
         software in the future.
         Documentation for software in this category shall meet all requirements of this
         Specification.
         Category B:
         Application-independent software, that is, fixed system software that is used in
         multiple applications (e.g., operating systems), or software that is encapsulated
         in a replaceable component (e.g., intelligent power modules). Category B
         software must be of an existing, service-proven design.
         Documentation for software in this category may be exempt from certain
         Specification requirements, only upon review and acceptance DTC.
The placing of software design documentation details, such as proprietary source code
or compilers, in an escrow account, in lieu of submittal to Authority, may be permitted,
subject to DTC acceptance, provided that sufficient software information is provided
(submitted and/or shown to an accepted reviewer) to enable DTC to evaluate overall
system performance.
Software escrow shall be implemented through the Software Escrow Agreement.
All escrowed software for the project shall be escrowed with a single software escrow
agent accepted by DTC.
The Contractor shall conduct a Software Escrow Verification Testing for all escrowed
software.
Software Escrow Verification Testing shall, at a minimum, verify that all software and
developmental tools have been escrowed to compile, link, or otherwise generate the
firmware, object code, P-Code, executable code, or whatever is required to run on the
vehicle system or portable test equipment or other software-based system supplied by
the Contractor or its subcontractors.
The escrowed software design, documentation details, documented source code, etc.,
shall be made available to DTC for its own use.

3.34.1        Non-Commercially Available Software

The Contractor shall submit, for acceptance, a Software Quality Assurance Plan
(SQAP) in accordance with ANSI/IEEE Standard 730. The plan shall include the
submittal and acceptance of the following documents:
         1.     System Functional Description,
         2.     Software Requirements Specification (SRS),
         3.     Software Design Description (SDD),


Issue Date: 3/28/05                      3-34
IFB 4-002 TECHNICAL SPECIFICATION                   3 - MATERIALS AND WORKMANSHIP


         4.     Software Verification and Validation Plan (SVVP),
         5.     Software Verification and Validation Report (SVVR),
         6.     Software Configuration Management Plan (SCMP), and

3.34.2        User Documentation.

With the exception of the System Function Description, these documents are those
required by ANSI/IEEE Standard 730.
Certain document submittal requirements may be waived, as accepted by DTC, for
software classified as Category B, as defined above.
The SRS shall be in accordance with ANSI/IEEE Standard 830.
The SDD shall be in accordance with ANSI/IEEE Standard 1016. In addition, the final
SDD shall include implementation details required by ATA Specification No. 102,
through all levels to Level 6. The levels defined in ATA No. 102 are summarized below
only for information:
         Level 1: Computer description and operation
         Level 2: Software architecture, basic program and functions
         Level 3: Detailed flow information
         Level 4: Annotated compiler/assembly listing
         Level 5: Detailed memory map and listing
         Level 6: Input/output port map
After original acceptance, changes to the software shall be formally submitted for
acceptance by DTC, prior to implementation. The software documentation shall be
revised concurrently with software changes.
All software shall be provided to DTC on CD-ROM.

3.34.3        Commercially-Available Software

Some software supplied under this procurement may be commercially available to a
wide variety of users.       Examples include operating systems supplied by chip
manufacturers and data base software for wayside fault analysis. The Contractor shall
submit a list of software that is commercially available to the general public. DTC shall
determine which software will be classified as commercially available.
For commercially-available software, software documentation requirements are limited
to the following:
         1.     The original data storage/transfer media (CD-ROM or diskette), functional
                and usage details,
         2.     All provider manuals, and
         3.     All licenses required for Authority site use.


Issue Date: 3/28/05                       3-35
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


The Contractor shall incorporate training on how the software is to be used in the
specific situation for which it was provided, as part of the Training Program.

3.34.4     Configuration Control

The Contractor shall develop a Configuration Control Plan for tracking software changes
to cars on Authority property until final acceptance of the entire fleet. This plan shall be
submitted for accepted by DTC, and may be incorporated in the Contractor’s SCMP. It
shall be consistent with the Contractor’s approach to configuration control of hardware
and require similar acceptance and tests.
All software shall be identified by a name and a unique version number and date. The
name shall identify the equipment into which the software is installed. Every change to
software shall be reflected in an update to the version number and date.

3.34.5     Software Maintenance and Related Tools

DTC retains the right to perform software modifications.
All software for this vehicle shall be delivered to DTC on CD-ROM or diskettes, except
as specified above. Final versions of all software shall be delivered to DTC on five (5)
Master CD-ROMs, capable of being copied by DTC to meet operation and maintenance
requirements of the equipment.
Upon the implementation of any revisions to software throughout the warranty period
after the submittal of the Master CD-ROMs, the Contractor shall submit five (5) revised
master CD-ROMs containing all the latest versions of all software.

3.34.6     Test Equipment Software

For custom software that is resident in test computers, either Diagnostic Test
Equipment (DTE) or Portable Test Equipment (PTE), the Contractor shall provide to
DTC a license for use of the software for the accepted purposes of this Contract.
Licenses shall not be linked to specific hardware serial numbers.
Documentation for the portable interface equipment software shall be furnished.
DTE and PTE software shall be based on Microsoft Windows® 2000 operating system.
If the Contractor determines a better-suited operating system, it may submit a request to
DTC for consideration.

3.35     WELDING

3.35.1     Responsibility

The Contractor shall be responsible for the quality of the welding done by its
organization and its subcontractors. All welders employed in the making of welds on
structures or products built under this Specification shall be tested to determine their
ability to operate the welding equipment used during production and to determine their
ability to produce satisfactory welds of the types required herein.


Issue Date: 3/28/05                     3-36
IFB 4-002 TECHNICAL SPECIFICATION                3 - MATERIALS AND WORKMANSHIP


The Contractor shall submit test procedures for DTC review and approval.
Welders shall have minimum qualifications as identified by ASME Code "Welding and
Brazing Procedures and Performance Qualifications" or equivalent AWS procedures.

3.35.2     Welding Rod

Welding rod, wire, or filler metal shall be chosen with respect to make, type, and size by
the Contractor for the specific application.
Should the suitability of welding rods, wire electrodes, or filler metal be questioned, the
provisions of Chapter 95 of the AWS Welding Handbook shall govern.

3.35.3     Heat Treating

Parts rotating at high speeds or parts subject to shock and/or vibration such as end
under frames shall be stress relieved after welding.

3.35.4     Welding Procedures

All welded connections shall be described on the construction drawings for the
passenger cars prepared by the Contractor and submitted for DTC review and approval.
Standard weld symbols shall be used to define type, pattern, and size for each weld.
Stainless steel parts shall be joined by resistance welding or by arc welding.
Resistance welding procedures shall employ accurate control of current, time,
electrode, size and shape, and tip force to produce uniform welds of specified strength,
which will not be subject to surface corrosion.
The strength of all resistance welds shall exceed the American Welding Society
Standards by a minimum of 20%.
The Contractor shall treat surface marks resulting from welding to eliminate, to the
extent possible, visible defects and discoloration in the finish surface.
In areas where space is restricted, resistance welding of components may be replaced
with Huck bolted connections. Each location shall be subject to prior DTC review and
approval.
The Contractor shall submit the design of individual connections for acceptance.
Torch cutting holes in any part of passenger car assembly or components is specifically
prohibited.
                                      End Section




Issue Date: 3/28/05                     3-37
IFB 4-002 TECHNICAL SPECIFICATION        3 - MATERIALS AND WORKMANSHIP




                         Intentionally Left Blank




Issue Date: 3/28/05            3-38
IFB 4-002 TECHNICAL SPECIFICATION                    4- STRUCTURAL AND FRAMING



SECTION 4             STRUCTURAL AND FRAMING
4.1    GENERAL

The carbody is a modular design fabricated over an aluminum frame with aluminum skin
and molded fiberglass end caps. The exterior of the carbody including the underframe is
primed and painted. Exterior markings are paint applied.
The carbody shall be reconditioned and all necessary repairs made to correct damage
and defects, to ensure water tightness, and to provide an appearance consistent with a
well-maintained passenger-carrying vehicle.
Any replacement of body components or underfloor apparatus shall be done in such a
manner as to preserve all present side and overhead clearances with respect to
external objects, and to preserve clearances between trucks and the carbody or
underfloor apparatus, except as may be otherwise noted.
The car shall be detrucked and the carbody exterior shall be thoroughly cleaned,
inspected for cracks and corrosion, and given a water tightness test. Special attention
shall be given to those areas exhibiting past leakage, such as window openings, end
cap covers and equipment compartments. All leaks shall be repaired.
The Contractor shall thoroughly survey each car structure for hidden damage. Cars 07,
08 and 11 have previously sustained collision damage to the end caps. The collision
damage has been repaired. A survey report identifying hidden structural damage shall
be submitted to DTC for review and approval prior to performing any repairs.
Structural damage which is not the result of exterior damage or other visible
abnormality, and could not be anticipated, shall be considered as extra work and treated
in accordance with the Terms and Conditions of the Contract.

4.2    UNDERFRAME

The underframe consists of a 6000 series aluminum alloy extrusion members and
components with front and rear steel anti-climber sections.
 All exposed areas of the underframe, including the end underframe weldments, center
sections of underframe and truck bays, shall be thoroughly cleaned by grit blasting or
other approved method, inspected, and repaired. The procedures for cleaning and
repair work shall be submitted for review and approval. A joint inspection with DTC shall
be performed after the under frame is cleaned.
Jacking pads shall be inspected for wear and deterioration. All jacking pads shall be
reconditioned.
All connections between steel and aluminum components shall be thoroughly inspected.
Metal corrosion and deterioration of isolating materials shall be repaired.
Highly stressed structural members and equipment support structures shall be
inspected by non-destructive methods. The Contractor shall identify the highly stressed
areas and submit the inspection procedure(s) for approval.


Issue Date: 3/28/05                    4-1
IFB 4-002 TECHNICAL SPECIFICATION                    4- STRUCTURAL AND FRAMING


Unused underfloor openings shall be sealed.
The underframe shall be primed and painted in accordance with Section 16 after
satisfactory completion of all repairs.

4.3    TRUCK ATTACHMENTS

Existing truck attachments and fasteners shall be cleaned, inspected, and repaired or
renewed.
Suspected cracks or separations shall be examined by dye penetrant testing.
Where damage or weld repairs compromise the structural integrity of the attachments,
they shall be renewed or replaced with a design accepted by DTC. Localized damage
repair shall be done only after submittal of the repair procedures for DTC review and
acceptance.

4.4    UNDERFLOOR EQUIPMENT ENCLOSURES

All underfloor equipment enclosures shall be removed from the car.
Mounting brackets shall be inspected and reconditioned. New equipment mounting
fasteners and associated mounting components shall be applied. Mounting fasteners
shall be torqued in accordance with OEM specifications.
Clearances for any newly installed/reconfigured equipment shall be checked to verify
that, under worst case dynamic conditions of the car, there is no infringement on the
underfloor clearance limits.
Maintenance clearances for newly installed/reconfigured equipment shall be checked
for ease of maintenance access.

4.5    OUTER SHELL

The outer shell including the roof and sidewall assemblies shall be inspected and
reconditioned. Minor dents, scratches, gouges, and surface deformities shall be
repaired and filled with an approved epoxy filler and ground smooth.
Missing and damaged fasteners shall be renewed. All seams shall be resealed with a
sealant compliant with Section 3. The original sealant was Tremco JS 709.
Particular attention shall be given to repair of areas around door and window openings
to insure proper weather seal of reassembled components.

4.6    COLLISION POSTS

The collision posts and adjacent structure shall be thoroughly cleaned and inspected for
corrosion, cracks and weld separations and repaired. Repairs shall retain the strength
of the original construction.
Generic procedures for cleaning and repair, if necessary, shall be submitted to DTC for
review and Approval.


Issue Date: 3/28/05                    4-2
IFB 4-002 TECHNICAL SPECIFICATION                     4- STRUCTURAL AND FRAMING


Drain hoses and fittings shall be cleaned, inspected and repaired or renewed.

4.7    END CAPS

The fiberglass end caps shall be removed for reconditioning and resealing. The
Contractor may submit an alternative method of resealing the end caps without removal.
The end, side and roof framing exposed after removal of end caps shall be cleaned,
inspected and repaired for any corrosion damage.
The framing shall then be repainted before re-application of end caps.
Equipment access covers in the nose caps shall be reconditioned. All seals and
fasteners shall be replaced.
After re-application and before carbody painting, the end cap to carbody connection will
be re-sealed at the butt joints and roof with Sika-Flex 221 Elastic Adhesive/Sealant or
equivalent.
The fiberglass end caps shall be cleaned and minor damage filled with body filler,
sanded, primed and painted in accordance with Section 16.

4.8    INSULATION

Exposed thermal and acoustic insulation shall be inspected for deterioration and water
damaged. Damaged insulation shall be renewed. Samples of the renewal insulation with
material certifications shall be submitted for DTC review and approval.

4.9    SIDE TRIM ASSEMBLIES

The side trim assemblies shall be reconditioned and painted consistent with the car
interior. All hinges and latches shall be reconditioned. All fasteners shall be renewed.

4.10   SIDE WINDOWS

The existing window rubber frame assembly shall be renewed.
Damaged, clouded or de-laminated Window panes, dead lights, shall be renewed if the
defect extends more than 1.0 inch (2.54 millimeters) into the viewing pane from the
edge of the framing rubber. An estimated 20% of the window panes shall require
replacement. Unapplied window panes within the 20% renewal limited shall be accepted
into DTC inventory as part of this Contract.
Window glass shall be Hi-Density laminated Safety Glass.

4.11   HAND HOLDS AND SAFETY BARS

Exterior vertical handholds shall be reconditioned.




Issue Date: 3/28/05                     4-3
IFB 4-002 TECHNICAL SPECIFICATION                     4- STRUCTURAL AND FRAMING


4.12   FLOOR PANELS

Floor panels are composed of light weight, honey-combed, aluminum-backed
assemblies. The floor covering, adhesive and loose leveling material shall be removed.
Floor panels shall be thoroughly cleaned to remove accumulated dirt and adhesive
residue. Floor panels, seams and fasteners shall be inspected. De-laminated panels,
panels with damaged seams/seals and panels that exhibit 0.125 inches (0.30
millimeters) or more of deflection in the centers shall be renewed. It is estimated that
less than 20%of floor panels shall require renewal.
An approved floor leveling filler material compliant with Section 3 shall be used to fill
voids and level the floor. The leveling material shall be impervious to moisture and shall
be sanded smooth prior to applying the floor covering.

4.13   SIDE DOOR THRESHOLD PLATES

Passenger side door threshold plates are extruded aluminum assemblies. Threshold
plates shall be reconditioned. The grouting material shall be replaced with a skid
resistant grouting. Safety striping shall be applied in accordance with ADA
requirements.
                                    End of Section




Issue Date: 3/28/05                     4-4
IFB 4-002 TECHNICAL SPECIFICATION                                           5- INTERIOR



SECTION 5             INTERIOR APPOINTMENTS
5.1    GENERAL

Existing interior configuration shall be retained and reconditioned. All materials
applied by the Contractor within the interior of the DPM vehicles shall comply with
the smoke, flame and emissions propagations specified in Section 3. Current
material certifications, less than 5 years old, shall be provided by the Contractor for
DTC review.
All interior apertures, features and appointments, whether specified herein or
omitted, shall be brought into full compliance with the Americans with Disabilities Act
(ADA) as part of this Contract. Compliance shall include the requirements for
access, lighting levels, high visibility warning strips, side door operation
annunciation, non-slip surfaces, and handrails as required by ADA.
The floor covering shall be renewed.
All traces of graffiti shall be removed from the car. Wall panels and ceiling panels
shall be reconditioned.
The seating arrangement shall be retained. Seats and seat bases shall be
reconditioned.

5.2    FLOOR

The floor covering, stair nosing and trim shall be renewed. The existing floor
covering shall be removed and discarded.
Contractor shall provide two (2) sets of samples of selected floor covering materials
for review and acceptance by DTC prior to ordering material.
Damaged floor panels shall be renewed in accordance with Section 4. All redundant
panel openings shall be sealed by application of glued plugs. The procedure shall
be submitted to the DTC for review and acceptance.
A leveling compound, Dex-O-Tex or equivalent, shall be applied over the passenger
area floor. The floor shall be sanded smooth and thoroughly cleaned to remove dirt,
sanding residue and adhesive residue before applying a new floor covering.
A single sheet of smooth textured, anti-skid, RCA transit grade vinyl flooring shall be
applied over the entire floor surface including equipment compartments and under
seat pedestals. Seams shall be avoided except for transitions in floor height. Color of
the flooring material shall be TBD.
Stair nosing consistent with the floor covering shall be applied at all passenger areas
at transitions in floor height.
Safety striping shall be applied in accordance with ADA requirements.




Issue Date: 3/28/05                     5-1
IFB 4-002 TECHNICAL SPECIFICATION                                          5- INTERIOR


Floor covering shall be laid in accordance with the best practices of the industry and
with proper allowance for expansion. Sheet floor covering shall be firmly secured to
the floor surface using an adhesives and procedures recommended by the
manufacturer of the floor covering.
Special care shall be taken to bond and seal the covering along all joints and
exposed edges to ensure that the floor covering does not buckle or separate
because of ingress of water during inclement weather and cleaning operations.
All cutouts shall be collared and all penetrations shall be ferruled.

5.3     WALLS AND CEILING

All materials to be retained shall be carefully cleaned, inspected, and repaired or
replaced, as required. Repair procedures shall be submitted for DTC approval.
All replacement materials shall be the same thickness, color, and finish as the
material being replaced, unless otherwise specified.
To compensate for color fading, new panels shall be matched to existing panels to
provide a consistent color application and appearance by car.
Repair and refinishing material and procedures for reconditioning side walls,
equipment compartment walls, windscreens and ceilings shall be submitted for DTC
approval prior to commencing work.
Damage or water soaked insulation exposed as part of interior reconditioning shall
be renewed.

5.3.1      Window Masks and Side Liners

Existing window masks and side panels shall be replaced. Panel surfaces shall be
graffiti resistant. The color and finish shall be TBD.
The Contractor shall submit material samples wall materials and application method
for DTC approval prior to ordering materials.

5.3.2      Equipment Compartment and Bulkhead Panels

The interiors of the equipment compartments shall be cleaned.
Wall and compartment door surfaces facing passengers shall be reconditioned and
finished in accordance with Section 5.3.1. Wall colors shall be coordinated with the
rest of the interior, subject to DTC approval.
The sliding door shall be removed as specified in Section 7. The door opening into
the equipment locker shall be sealed and finished to complement the car interior.

5.3.3      Windscreens

Windscreens shall be thoroughly cleaned and reconditioned. Panel finish shall be
consistent with and complement the interior.


Issue Date: 3/28/05                      5-2
IFB 4-002 TECHNICAL SPECIFICATION                                          5- INTERIOR


Ventilation grills shall be cleaned and polished. Damaged ventilation grills shall be
renewed.
Hinges and latches on access doors shall be reconditioned.
Windows shall be polished to remove minor scratches and abrasions. Deeply etched
or scratched windows shall be renewed.
The wheel chair locking mechanism shall be reconditioned.

5.3.4      Ceiling Panels

The existing panels shall be cleaned to remove graffiti ghosts and repaired or
replaced as required.
Hinges, fasteners and T-locks shall be renewed.
Grills shall be polished and secured with new fasteners.

5.4     STANCHIONS AND HANDRAILS

All stanchions and handrails shall be reconditioned.

5.5     SEATING

DPM vehicles have seating capacity for 34 passengers. The seats are longitudinally
mounted on each side of the aisle on pedestals and over floor equipment
enclosures. Two pair of seats flip to provide ADA wheelchair parking locations with
wheelchair clamps.
The existing seating arrangement shall be retained. Seats, bases and pedestals
shall be reconditioned.

5.5.1      Single and Double Seats

The seats have fabricated stainless steel frames with vinyl seat and back inserts.
The shells shall be cleaned, polished and repaired.
The seat and back inserts shall be renewed. The color of the inserts shall be
coordinated with and be consistent with the interior design. Color samples and
samples of insert material with material certifications shall be submitted for DTC
approval prior to ordering.

5.5.2      Pedestals

Seat pedestals shall be reconditioned and reapplied with new fasteners.

5.5.3      Seat Bases

The seat bases form equipment compartments for floor heater assemblies, car
batteries, PCU electronics, and the brake control unit.


Issue Date: 3/28/05                    5-3
IFB 4-002 TECHNICAL SPECIFICATION                                        5- INTERIOR


The interiors of the bases shall be cleaned and reconditioned. Particular care shall
be taken to clean corrosive materials in the battery compartment and repair or renew
any damaged structure and components.
Ventilation tubes in the battery compartment shall be renewed.
All fasteners shall be renewed.

5.5.4      ADA Locations

The flip seats shall be reconditioned. Latches and hinges shall be repaired or
renewed.
Wheelchair clamps shall be reconditioned or renewed as required. The clamps shall
be tested for ease of operation and serviceability.
                                  End of Section




Issue Date: 3/28/05                   5-4
IFB 4-002 TECHNICAL SPECIFICATION                                         6 – COUPLERS



SECTION 6             COUPLERS AND DRAFT GEAR
6.1    GENERAL SCOPE

Detroit APM Vehicles are equipped, at each end, with a Dellner ICTS Type 40
Coupler and associated draft gear.
Couplers and draft gear shall be completely overhauled in accordance with The
Detroit Type 40 & 40A Automatic Couplers, Overhaul Specification Document No
150403-OHS-000 for Dellner Couplers P/N 152480. Detroit APM Vehicles Car
Heavy Maintenance Manual Chapter 12 shall be used as a reference for Component
Inspection and Repairs.
The intent of the overhaul is to Recondition and upgrade the couplers to an “as new”
condition.
In addition to the overhaul exercise, Dellner Couplers recommends implementing
upgrades to the steering mechanisms and electric coupler cables. These upgrades
were integrated into the type 40 style couplers since the original supply of the
equipment.

6.2    COUPLERS – MECHANICAL (PART NO. 160137)

The coupler heads, manufactured by Dellner, are made of high tensile steel and are
of an interlocking type.
Couplers shall be completely disassembled, cleaned, inspected, and gauged to
determine if they are suitable for reused and/or repaired. If any parts are out of gage,
the Contractor must submit a procedure for approval before making repairs to
reclaim any mechanical coupler body parts.
All cast portions on 3 of the couplers selected at random by DTC shall be thoroughly
inspected by magnetic particle inspection (wet method). All couplers shall be 100%
visually inspected for damage.
After inspection, repair and cleaning, the mechanical coupler shall be primed with
Dupont, Corlar Epoxy red primer #825-Y-9031, and painted with a top coat of
Dupont Imron Polyurethane black, #326-Y-67640 applied per Dellner Instruction
AI904.
The following components shall be renewed; link, springs, pins, hook plate,
bushings, main pin and left & right heater elements.

6.3    COUPLERS – ELECTRICAL, RIGHT & LEFT (PART NO. 160117)

The electrical coupler portion shall be removed. All fixed contact pins, block and
moving contact pins, along with associated hardware and elastomers shall be
renewed.




Issue Date: 3/28/05                     6-1
IFB 4-002 TECHNICAL SPECIFICATION                                        6 – COUPLERS


 Replace the main electrical control cable assembly with new 75 single stand wire
with PMA conduits. Replace cable sealing gland with cable sealing gland PMA
grommets.
Inspect junction boxes and wiring and renew seals on junction box lids. Paint inside
of electrical coupler head housings, and any re-work on junction boxes with white
insulating paint.
The electrical couplers and suspension devices are to be removed from the
mechanical head and disassembled according to the heavy repair manual. The
wires leading to the fixed and moving contacts shall to be disconnected to prepare
the electric couplers for the implementation of cable upgrade.

6.4    DRAFT GEAR (PART NO. 160135)

The draft gear assembly shall be removed from the car and disassembled according
to the heavy repair manual. The assembly shall be cleaned, inspected and
reconditioned in accordance with Dellner 150403-OH-000.
All draft gear elastomeric springs, elastomeric components, bushings, clamps,
associated hardware shall be renewed. All brackets, plates, housings, yoke,
flanges, trunnions, shall be cleaned, inspected and reconditioned if still serviceable.

6.5    COUPLER TO CARBODY ATTACHMENTS

The carbody to coupler hardware shall be renewed.

6.6    MECHANICAL AND REMOTER ELECTRICAL UNCOUPLING FEATURES

Both manual uncoupling assemblies on the coupler, and the electrical remote
feature I the car, shall have all related parts reconditioned.

6.7    COUPLER CENTERING DEVICE (PART NO. 160130)

All components of the coupler centering device shall be reconditioned. The ball joint
arms shall be replaced with ones with grease fittings. The fittings shall be oriented
towards the outside of the car to facilitate easy re-lubrication.
Shock absorbers shall be renewed.
Trunions shall be modified to include lubrication fittings at pivot points and
reconfiguration of the key slot to minimize failure. Design of the trunion modification
shall be reviewed by DTC.

6.8    UNCOUPLING DEVICE (PART NO. 160143)

The existing uncoupling motors are dated, and subsequent replacements have
proven to be unsatisfactory. The Contractor shall propose a replacement motor for
DTC review and approval. The replacement motor shall utilize metallic gears.



Issue Date: 3/28/05                     6-2
IFB 4-002 TECHNICAL SPECIFICATION                                       6 – COUPLERS


The uncoupling device is to be disassembled according to the heavy repair manual.
Inspect, test and renew the limit switches, and replace the motors with a new
improved design. Renew the bearings, bushings elastomers, hardware and bearing
plates.

6.9    OPERATING DEVICE (PART NO. 160122)

The operating device is to be removed and disassembled according to the heavy
repair manual. Inspect, test and requalify the linear motor. Renew the limit switches,
the bellows, bushings and any hardware.

6.10   TERMINAL BOX INSPECTION (PART NO. 152146)

The terminal box is to be removed and disassembled according to the heavy repair
manual. The wiring is to be disconnected at the terminal block. After continuity test,
re-use terminal box cables. Renew box seals.

6.11   FRONT FACE OF ELECTRIC COUPLER (PART NO. 160128)

The front face of the electric coupler is to be removed from the mechanical coupler
head and disassembled according to the heavy repair manual. The fixed contact
block, fixed contacts, moving contacts, retaining rings, and all associated elastomers
and hardware are to be renewed.

6.12   OTHER COMPONENTS

Renew the rubber cover (part no. 160124) and the cable fairlead (part no. 160190).


                                  End of Section




Issue Date: 3/28/05                    6-3
IFB 4-002 TECHNICAL SPECIFICATION                 6 – COUPLERS




                       Intentionally Left Blank




Issue Date: 3/28/05             6-4
IFB 4-002 TECHNICAL SPECIFICATION                                            7 – DOORS



SECTION 7             DOORS
7.1     GENERAL SCOPE OF DOOR SYSTEM OVERHAUL

The Door System on the DTC vehicles consists of four sets of passenger side door
assemblies (two on each side), two end doors, two emergency step assemblies, an
interior sliding pocket door and an interior equipment locker door. The side doors
are powered, utilizing a Faiverely side door system with electric door operators. The
end doors, emergency step assemblies, and interior sliding pocket and equipment
locker doors are manually operated.
All door panels and associated latches and hardware shall be reconditioned, except
for the sliding pocket door which shall be removed and the pocket sealed.
The side door operator motor, track and control system shall be replaced with a new
system for improved reliability and maintainability.
The emergency steps shall be reconditioned.

7.2     SIDE DOORS

Two side door assemblies are located on each side of the vehicle, with each side
door consisting of two sliding leaves that are controlled by signals sent to each door
control unit (Electronic Control Unit [ECU]). Status signals from the doors' ECU are
received by the VOBC. The VOBC sends commands back to the door Control Unit
that directly governs the doors. After a command has been received via the
trainlines from the VOBC, the passenger doors slide along their track.
The passenger side doors are bi-parting, i.e., when the doors open, the panels move
apart; and when the doors close, the panels meet in the middle of the doorway. The
panels slide on door tracks located both above and below the door opening. A
Faiveley belt driven screw-drive door operating system opens and closes the doors.

7.2.1      Side Door Performance

Side door performance shall conform to ADA and ASCE 21-98, APM – Part 2,
Section 7.8 requirements. Doors shall not open when DPM vehicles are in motion.
Electronic proximately switches shall be utilized to sense door position. Mechanical
micro-switches shall not be permitted.

7.2.2      Side Door Panels

The side door panels are composed of an aluminum skin bonded to a phenolic-
impregnated, kraft paper, honeycomb core framed by special profile aluminum
extrusions. The upper half of each leaf is glazed, and a kickplate is located on the
inside at the bottom. Note that the side door panels are not interchangeable and
must be refit to the same door opening from which they were removed.



Issue Date: 3/28/05                    7-1
IFB 4-002 TECHNICAL SPECIFICATION                                           7 – DOORS


The side door panels shall be reconditioned. Dents or cuts in the panels shall be
repaired to be smooth and watertight. The reconditioned panels shall be painted or
decaled to match the rest of the vehicle interior and exterior, in accordance with
Section 16.
The side door windows shall be inspected for cracks, discoloration, hazing or
deterioration, and renewed as required. Side door windows are considered
acceptable for reuse if the defect is not more that 1.0 inches (2.54 mm) from the
edge of the rubber glazing. The Side door window glazing rubber shall be renewed.
Side door windows shall be modified for ease of renewal. The design shall be
subject to DTC review.

7.2.3      Side Door Seals

The door leading (inner) edges are equipped with elastomeric extrusions which
include an air-wave sensitive edge system. These leading edge seals shall be
replaced with new edge seals provided in accordance with recommendations by the
door operator supplier.
All other side door rubber edging or seals shall be renewed including the rubber
lower corner seals on the threshold and the rubber-tipped door seal angles secured
to the outer trailing edges of the door leaves. The brush seals located on the top
and bottom of the door opening shall be renewed.

7.2.4      Side Door Track and Operating Systems

The side door operator and upper track systems shall be replaced with a suitable
currently available replacement system. The new side door operator system shall
be designed to be installed in the same area as the existing door operator system
without major door, body or structural changes. The new door operator system shall
interface with the ECU and the VOBC to provide for safe and reliable door operation.
The door operator motor shall be powered by the 37.5-Vdc low voltage system and
will provide for smooth opening and closing of the doors under all conditions with no
bouncing at either end of each stroke. The door operator drive shaft, operator
assembly, door hanger track assembly, door control unit and door panel carriage
assemblies shall be replaced as part of the new system.
The new door control system shall incorporate an electronic obstruction detection
system to replace the existing pressure wave sensitive edge system for improved
obstruction detection operation and reliability. When closing, vehicle door control
shall detect an obstruction of 1.0” or greater located at any point along the closing
edges. When such an object is detected, the door shall not lock and the interlocking
requirements of ASCE 21-96, APM – Part 1, Section 5.1.11, Departure Interlocks,
shall be met.




Issue Date: 3/28/05                    7-2
IFB 4-002 TECHNICAL SPECIFICATION                                             7 – DOORS


The new door operating system shall be an updated version of the door system
installed on the Vancouver Skytrain Mark I cars. It l features a belt drive linear door
operating system with modernized electronic door operation control systems that will
interface with the existing/proposed VOBC and HMP systems. It shall provide for
improved reliability and maintainability. Door operating systems provided by Faively,
Vapor and Curtis will be considered.
The lower door track system shall be reconditioned, including the renewal of all
seals, rollers and bearing assemblies.

7.2.5      Side Door Emergency Systems

Each passenger door is equipped with an interior toggle cut-out switch behind a
hinged access panel in the door header cover, accessible by a crew key. The door
cut-out switch shall be renewed and the switch access door and lock assembly shall
be reconditioned.
Each passenger door has two interconnected emergency release handles (one
inside, one outside) to release the door locking mechanisms and to isolate the door
motor from its power supply.          The emergency release systems shall be
reconditioned. The force required to actuate the door emergency release system
and to manually open the doors (without power) shall not exceed 35 lbs. Manually
opened doors shall stay open in any position when the vehicle is stationary on any
grade up to 4%. Closing the doors shall cause the emergency release mechanism
to reset.
The breakable plastic covers and related gaskets and fasteners for the passenger
door emergency release handles shall be renewed.

7.3     EMERGENCY END DOORS

An emergency end door is located at each end of the car. Each end door includes a
window with a built-in demister, a windshield wiper motor and wiper, a door latch, an
interlocking switch, a gas spring assembly, and a pair of interacting seals. The
emergency end doors and associated frames shall be reconditioned.
The end door panels shall be inspected for dents and/or cuts and smooth, watertight
repairs made as required. The panels shall be repainted/decaled to match the rest
of the vehicle interior and exterior, as specified in Section 16. All end door seals and
gaskets shall be renewed.
The end door window glazing (with integral demister) and glazing shall be renewed.
The 37.5-Vdc windshield wiper motor assembly shall be reconditioned. The wiper
arm, blade and any gaskets or seals shall be renewed.
The emergency door hinges, hardware and latch assemblies shall be reconditioned
and lubricated. The end door gas spring assemblies shall be reconditioned or
renewed if defective. The end door interlock switches shall be renewed.



Issue Date: 3/28/05                     7-3
IFB 4-002 TECHNICAL SPECIFICATION                                           7 – DOORS


It shall be possible to manually open the emergency exit door from inside the
vehicle, and operate the emergency stair assembly with a force not to exceed 35 lbs.

7.4     EMERGENCY STAIR ASSEMBLY

The emergency stair assembly shall be reconditioned, including a thorough cleaning
and inspection/repair of all components.
All hinges, locks, latches, striker plates and stair rollers shall be cleaned,
reconditioned and lubricated. The emergency stair release cables and damper shall
be renewed. The anti-skid safety tape on the steps shall be renewed.
The fiberglass stair cover shall be reconditioned and finished in accordance with
Section 16.

7.5     SLIDING POCKET DOOR

The sliding pocket door assembly adjacent to the equipment lockers shall be
removed, including the door, upper and lower door tracks and door closer assembly.
The door pocket shall be cleaned of debris and the door pocket opening
permanently sealed in a manner that blends with the rest of the vehicle interior.
The floor where the lower door track is to be removed shall be filled with a suitable
compound and/or stainless steel cover plate and made level with the rest of the
vehicle floor. The patched area is to be covered with new flooring rubber in
accordance with Section 5.

7.6     EQUIPMENT LOCKER DOORS

All equipment locker doors shall be reconditioned, including all hinges, latches and
associated hardware. Any damaged panels shall be repaired.

7.7     DOOR CONTROL SYSTEMS

The operation of the passenger doors is controlled by the trainline signals from the
VOBC. The signals go via the ATC panel to the individual door control units.
The door control system shall be replaced with a new system provided by the door
operator manufacturer and installed per manufacturer’s instructions. The door
control system shall continue to interface with the VOBC and ATC systems. All door
control systems shall be reconditioned, renewed or replaced, as appropriate with the
installation of the new door operator system. The crew switches and hostling panels
shall be reconditioned. All limit switches and indicator light bulbs that remain from
the existing system shall be renewed.

7.7.1      Door Control System Features

The following features, subject to ADA requirements and regulations, shall be
incorporated into the door control system:


Issue Date: 3/28/05                    7-4
IFB 4-002 TECHNICAL SPECIFICATION                                            7 – DOORS


   •   Doors Opened Indication – When any side passenger or end door is opened,
       the Door Status Relay K1-DC, shall be de-energized, removing the Door
       Closed status indication to the VOBC and illuminating the red exterior Door
       Open lights. The train shall not be able to move when the doors are opened.
   •   Opening Cushion – When the passenger door leaves are 3-7/8” ± 3/8 inches
       from their fully opened position, the speed of the motor and door operating
       system shall decrease, reducing the opening speed of the door leaves, to
       prevent “bounce-back” of the door leaves.
   •   Doors Fully Open – When the passenger side doors are fully opened,
       providing a minimum clear opening of 30”, power to the door motor shall be
       cut via the ECU.
   •   Closing Cushion – When the passenger door leaves are 14 inches from the
       fully closed position, the door operator system speed shall decrease, causing
       a reduction of the door closing speed to prevent recoil or rebound of the door
       leaves. Door closing forces shall not exceed 30 lbs. for the full range of door
       motion.
   •   Doors Fully Closed – The passenger doors shall be considered fully closed
       when the door panels reach the fully closed position (0.4” apart). A locking
       mechanism shall hold the door in the closed position.
   •   Confirmation of Doors Closed and Locked – All four (4) passenger side doors
       and both (2) end doors must be closed and locked before the Door Status
       Relay K1-DC is energized, providing the Door Closed status indication to the
       VOBC and extinguishing the exterior Door Open lights, thus allowing the train
       to move.
   •   Emergency Switch – When either the interior or exterior emergency door
       release handles are pulled, the Door Status Relay K1-DC shall be de-
       energized.
   •   Door Status Lights – When any side passenger or end door is opened, the
       K1-DC relay is de-energized, resulting in the illumination of the two-door
       status lights located on the vehicle exterior. Additionally, when an end door is
       opened, the headlights on that end are illuminated.
   •   Parking Brake Interlock Relay (APBR) – The APBR is energized by the park
       brake relay (PBR) in the disc brake system when the park brakes have been
       applied. The APBR must be energized before its respective door motor can
       operate.
   •   Crew Switches and Hostling Panels – The doors shall be capable of being
       opened through the use of the crew switches or hostling panels.




Issue Date: 3/28/05                     7-5
IFB 4-002 TECHNICAL SPECIFICATION                                             7 – DOORS


   •    Door Opening/Closing Signals to Relay DCLR – The Door Control Latching
        Relay (DCLR), receives commands from the VOBC once the parking brakes
        have been applied. The opening commands are initiated by Central Control
        via the VOBC. The DCLR relay latches in both the Door Open and Door
        Close positions. To close doors, the relay is commanded to the Door Close
        position and remains latched and energized (except in EB situation) until the
        Door Open command is given.

7.7.2       Door System Interfaces

The door system shall interface with other vehicle control and operating systems to
provide for safe and reliable door operation. The door control unit (ECU) shall
interface with the following systems:
   •    VBOC – Sends command signals to the ECU and receives door status
        indication when all doors are closed and locked.
   •    Hostling Panel – With the vehicle in manual mode, a crewman can operate
        the sets of doors on either the right or left side of the vehicle.
   •    Health Monitor Panel – When a door system malfunction exists, the HMP
        indicates which doors are not locked and which doors are open.
   •    Circuit Breaker Panel – Houses the following circuit breakers for the doors:
        -   CB1-DC – power supply, rear doors
        -   CB2-DC – door indicator lights
        -   CB3-DC – power supply, front doors

   •    Low Voltage Relay Panel – Houses relays for the following: K2-DC, K3-DC,
        and K1-DC, the door Open/Closed status relays




Issue Date: 3/28/05                      7-6
IFB 4-002 TECHNICAL SPECIFICATION                                        7 – DOORS


7.7.3      Door System Failure Indications

The Health Monitor Panel (HMP) indicates the status of the doors by illuminating
LEDs. The HMP is in the front left compartment of the vehicle. Three lines connect
each passenger door control unit to the HMP. The LEDs related to the door status
shall be as follows:


   LED Number                                Source of Alarm
         A8           Door Open Not at Station
         C1           Front-Left Door Not Locked (#1 Door)
         C2           Front-Right Door Not Locked (#2 Door)
         C3           Rear-Left Door Not Locked (#3 Door)
         C4           Rear-Right Door Not Locked (#4 Door)
         D1           Front-Left Door Open (#1 Door)
         D2           Front-Right Door Open (#2 Door)
         D3           Rear-Left Door Open (#3 Door)
         D4           Rear-Right Door Open (#4 Door)
         B8           Front-Left Door (#1 Door) Open Not at Station
         C8           Front-Right Door (#2 Door) Open Not at Station
         D8           Rear-Left Door (#3 Door) Open Not at Station
         E8           Rear-Right Door (#4 Door) Open Not at Station




                                  End of Section




Issue Date: 3/28/05                    7-7
IFB 4-002 TECHNICAL SPECIFICATION                 7 – DOORS




                       Intentionally Left Blank




Issue Date: 3/28/05             7-8
IFB 4-002 TECHNICAL SPECIFICATION                                                8 – HVAC



SECTION 8             HVAC
8.1    GENERAL SCOPE OF HVAC OVERHAUL

The Heating, Ventilation, and Air Conditioning (HVAC) System consists of a 28-kW
(96,000 BTU) ventilation and (AC) system and a 26-kW (89,000 BTU) electrical
heating system. The combined systems are designed to process recycled and/or
fresh air by controlling its temperature, cleanliness, and distribution to meet the year-
round comfort requirements of the passengers. The AC system consists of an
undercar compressor/condenser unit which supplies refrigerant through copper
piping to a ceiling-mounted, overhead evaporator blower unit. The heating is
accomplished by means of six thermostatically controlled electric floor heaters and
one overhead heater near the evaporator coil. The system is designed to operate
on a 600-VDC power supply and 37.5-VDC control voltage.
The Air Conditioning System (including the overhead evaporator heater) was
manufactured by Stone Safety Corporation.         The six floor mounted heater
assemblies were manufactured by Vapor Canada, Inc. Refer to the “Detroit
Downtown People Mover” Maintenance Manual, Chapter 7 – Environmental Control
for additional system information and maintenance procedures.
The AC compressor-condenser unit is mounted in a steel frame that is secured to
the underframe of the carbody by four sets of resilient mounts. The unit includes a
compressor, compressor motor, condenser coil, liquid receiver, and a filter drier
assembly, as well as a weatherproof refrigeration control box mounted on the
support frame. All compressor-condenser components will be reconditioned.
The evaporator coil and blower motor assemblies are located overhead in the center
of the car. The DC blower motor assembly is located behind a lighting fixture on the
right-hand side of the car. The evaporator coil is located above a ceiling panel in the
center of the car. The evaporator coil assembly will be pressure tested and
reconditioned. The blower motor assembly will be replaced with an AC blower motor
assembly.
A ductwork system within the ceiling of the car distributes the conditioned air
throughout the car from overhead diffusers. Fresh air dampers and duct assemblies
are located overhead at the four corners of the car. The ductwork shall be
thoroughly cleaned and sanitized. The fresh air dampers shall be reconditioned.
Electric heating units are located throughout the car. Most units are located under
the seat assemblies, but an additional heater unit is located overhead with the
evaporator coil. All heating units shall be reconditioned.
HVAC Control System is located in the front equipment locker. The HVAC Control
system shall be reconditioned and modified to inhibit operation of the refrigerant
compressor whenever the ambient temperature is below 40oF. .
All thermostats and temperature sensors shall be replace with solid state devices.




Issue Date: 3/28/05                      8-1
IFB 4-002 TECHNICAL SPECIFICATION                                                        8 – HVAC


System operation includes both normal and standby operation, according to the
following Temperature Sequence Chart, Figure 8.1-1.

                                  HVAC NORMAL OPERATION
   Temperature Rising Mode             Interior Temperature         Temperature Falling Mode
                                FULL COOL MODE (Air Conditioning)
Modulation Valve Energized                 77.0°F – 25.5°C
                                           75.0°F – 23.9°C        Modulation Valve De-Energized
                                PART COOL MODE (Air Conditioning)
Line Solenoid Valve Energized              73.4°F – 23.0°C
                                           71.4°F – 21.9°C        Line Solenoid Valve De-Energized
                                      VENTILATION MODE
             Overhead Evaporator Blower Motor Operating – No Heating and No Cooling
                                         HEATING MODE
OH Heat Contactor 2 De-Energized           68.0°F – 20.0°C
                                           67.0°F – 19.4°C        OH Heat Contactor 2 Energized
OH Heat Contactor 1 De-Energized           66.2°F – 19.0°C
                                           65.2°F – 18.4°C        OH Heat Contactor 1 Energized
Floor Heat De-Energized                    64.5°F – 18.0°C
                                           63.4°F – 17.4°C        Floor Heat Energized
Fresh Air Dampers Open                     60.8°F – 16.0°C
                                           59.2°F – 15.4°C        Fresh Air Dampers Closed


                                 HVAC STANDBY OPERATION
                                     No Cooling in Standby Mode
Fresh Air Dampers Open                     60.8°F – 16.0°C        Fresh Air Dampers Closed
Floor Heat De-Energized                     41.0°F – 5.0°C        Floor Heat Energize



                      Figure 8.1-1 – Temperature Sequence Chart




Issue Date: 3/28/05                          8-2
IFB 4-002 TECHNICAL SPECIFICATION                                              8 – HVAC


8.2     HEATING

8.2.1      Heating System Description

The vehicle heating system is composed of six compact electrical heater modules
mounted beneath the passenger seating and one overhead evaporator heating unit.
The floor heating units are mounted on the floor of the vehicle, three on each side; at
forward, center and rear locations. The evaporator heater unit is located overhead,
above the ceiling panels in the center of the car.
All floor heater units are single-stage units with one electrical element assembly
rated at 2-Kw, consisting of two elements rated at 200 volts each. To facilitate
operation from the 600-volt supply line, three heater elements are series connected,
with two elements within one heater unit, plus one element of another heater unit.
All motor-blowers for the floor-heating units operate from a separate power source of
27.5-volts, 3Ø, 60-Hz. A thermal cutout switch and thermal link is provided for
thermal protection on each floor heater unit. Ducts diffusers are provided to
distribute the heated air at floor level. The center car heater units also distribute
heated air to diffusers beneath the sidebody windows.
The overhead electrical heater assembly is mounted downstream of the evaporator
coil. The overhead heater system is a two-stage system with two individual 7-Kw,
600-Vdc heating elements, that when operating together provide up to 14-Kw of heat
to air supplied from the evaporator blower motor assembly. The heating elements
are composed of two-row, open-design-type nickel chromium (corrosion-proof) bare
wire element with ceramic insulators. A vane switch, situated in the air flow will
operate to inhibit energization of the heater elements if the blower motor fails. The
overhead electrical heaters are used only during winter operation and do not provide
reheat capabilities during summer AC operation.

8.2.2      Floor Heaters

All floor heater units shall be reconditioned. Cover hardware shall be renewed.
Heater unit box assemblies shall be cleaned and reconditioned. Renew grommets,
wire guards and fasteners. All heater covers, grills, diffusers and ducts shall be
cleaned and sanitized.
All floor heater cover assemblies shall be modified to include hinged access panels
to allow for the easy removal of the fan, heating element and heater fuse
assemblies, without removal of the entire cover assembly. The hinged access
panels in the cover assemblies shall be secured with captive tamper-proof fasteners.
Fan assemblies shall be tested for functionality. Connect 27.5-Volt, 3-Phase, 60-Hz,
power supply to the fan motor terminals M1, M2, and M3, adjusting connections for
proper fan rotation. The fan output as measured with a stroboscope shall be 3440
RPM + 10%. Renew hardware attaching fan assemblies to heater box assemblies.




Issue Date: 3/28/05                     8-3
IFB 4-002 TECHNICAL SPECIFICATION                                              8 – HVAC


Electrical heater element assemblies shall be bench-tested for functionality.
Measure the resistance of each element:
      •   H1 to H2; Resistance should be 40 ohms, ± 5 ohms (cold)
      •   H3 to H4; Resistance should be 40 ohms, ± 5 ohms (cold)
Electrical heater element assemblies outside these measurements that exhibit signs
of overheating, burning or corrosion shall be renewed. Note that individual electrical
heating elements on this assembly are not replaceable. Renew hardware attaching
electrical heater element assemblies to the heater box assemblies.
Renew all floor heater unit fans, thermal cutout switches and the thermal fuse links.

8.2.3        Overhead Heater

Recondition the overhead electric heater elements. Renew any assemblies that are
non-functional or exhibit signs of overheating, melting or corrosion. Note that two
versions of the heater may be found in service; they are not interchangeable due to
wiring changes. Order replacement heater elements according to the heater being
removed.
Renew grommets, wire guards and fasteners. Renew terminal blocks, insulator
strips, cover strips and hardware. Wiring and lugs between heating elements and
terminal blocks shall be renewed and shall be high temperature resistant.
Renew the overhead electric heater over-heat protection switch (KLIXON), the two
high voltage heat limiter fusible links (one for each heater element) and the vane
type air flow switch.

8.3       VENTILATION

8.3.1        Ventilation System Description

The ventilation system includes four fresh air ducts located at the upper corners of
the vehicle exterior. Two separate emergency air intake ducts are located on the left
side of the vehicle, one forward of the front fresh air duct, and one on the rear fresh
air duct. The fresh air ducts are equipped with motor-operated dampers which close
at temperatures of 60.8°F (16°C) or lower to prevent outside air being drawn into the
vehicle interior. The emergency air intake ducts are equipped with fans that are
operated from the car’s 3Ø, 27.5-Vac system, which will provide fresh air to the
vehicle interior in the event of a failure of the evaporator blower motor.
An overhead ceiling ducting system provides for distribution of air conditioned and
heated air throughout the entire length of the passenger compartment.




Issue Date: 3/28/05                     8-4
IFB 4-002 TECHNICAL SPECIFICATION                                            8 – HVAC


8.3.2      Fresh Air Intake and Emergency Air Intake Ducts

Recondition all fresh air duct systems, including the duct housing, the damper and
the damper motor. This includes cleaning of the assemblies and operational testing
of the damper assemblies. Renew all seals, flexible duct connections and
associated hardware.
Test the fresh air dampers to ensure that they close at temperatures at or below
59.2°F (15.4°C).
Recondition the emergency air intake duct systems, including the damper and
blower motor assembly. This includes cleaning of the assemblies and operational
testing of the damper and blower motor assemblies. Renew all fans, seals, flexible
duct connections and associated hardware.
Test the emergency air intake damper motors to ensure that they activate when the
evaporator heater airflow switch opens when the blower motor is activated.

8.3.3      Ceiling Ducting and Diffuser Assembly

The ceiling supply ducts shall be reconditioned. Check for duct air leaks at seams
and repair or renew as required. Renew all flexible ducts or seals connecting the
ceiling duct system to other HVAC system components. Inspect the fiberglass
thermal insulation that covers the ducting. Renew any insulation that is missing,
physically damaged or that exhibits signs of moisture or mold.
Recondition all diffusers and renew all diffuser attaching hardware.
Renew all air filters.
All ventilation ducts, plenums and diffusers shall be thoroughly cleaned, sanitized
and disinfected.

8.4     AIR CONDITIONING UNIT

The air conditioning system currently cycles on, as a system check, whenever the
vehicle first sees the application of 600 Vdc electrical power. The control system
shall be modified, to hold the air conditioning system off without causing on fault,
whenever the stand by heat thermostat is activated closed.
Air conditioning equipment shall be modified with low loss fittings and gauge access
ports.

8.4.1      Air Conditioning System Description

The air conditioning system comprises a 28-Kw (96,000 BTU, or 8-ton) system,
including an underfloor compressor-condenser unit mounted in a steel frame
secured to the underframe of the carbody and an evaporator coil and DC blower
motor assembly mounted overhead in the center of the drop ceiling area within the
passenger compartment.



Issue Date: 3/28/05                     8-5
IFB 4-002 TECHNICAL SPECIFICATION                                               8 – HVAC


The compressor-condenser assembly includes a compressor, compressor motor,
condenser coil, liquid receiver, a filter drier assembly, compressor start and run
resistors, and a weatherproof refrigeration control box mounted on the support
frame. The support frame is secured to the underframe of the carbody by four sets
of resilient mounts.    The compressor is a “Carrier”-manufactured 6-cylinder
compressor unit, equipped with an unloading system to provide for capacity control
of 100%, 66%, and 33%. The compressor motor operates on nominal 600-Vdc, is
16-HP, draws 25 Amps and has a rated speed of 1250 RPM.
The overhead evaporator unit comprises a motor-blower assembly, an evaporator
coil, two expansion valves, line and modulation control solenoid valves, a liquid line
strainer and a drain pan for condensate. Two different, but similar, generations of
evaporator and blower assemblies may be in service. Parts are generally
interchangeable between the two systems.
The refrigerant (R22) is circulated between the evaporator unit and the motor
compressor unit by copper piping routed inside the vehicle walls.
All repairs to the air conditioning unit are to be performed with personnel that are
EPA-certified for the repair of air conditioning units. Refrigerant shall be reclaimed,
cleaned and reused in accordance with manufacturer’s instructions and EPA
regulations.

8.4.2      Compressor

The compressor assembly, manufactured by Carrier (Safety P/N T-23293-1), shall
be reconditioned. This shall include complete disassembly of the unit, cleaning and
inspection of components to be reconditioned.
Renewal parts shall include, but not be limited to, all seals and gaskets, piston rings,
valves, unloader valve assemblies, oil fill and drain plugs, suction and discharge
shut off valves, crankcase heater assembly and all hardware. The crankshaft seal
assembly shall be renewed.
All other compressor components shall be reconditioned or renewed if beyond repair
or tolerances.
Renew the compressor crankcase oil charge with 9 US pints (4.3 Liters) of approved
oil per manufacturer’s recommendations. Charge the compressor with dry nitrogen
for storage until reinstalled in the vehicle.

8.4.3      Compressor/Condenser Fan Motor

The compressor/condenser fan motor, manufactured by Safety Electric Co. as P/N
T-8534, shall be reconditioned, according to manufacturers’ specifications, including
the removal of the armature from the motor case and a complete cleaning and
inspection of all motor components.




Issue Date: 3/28/05                     8-6
IFB 4-002 TECHNICAL SPECIFICATION                                            8 – HVAC


The compressor motor is rated at 16 HP, 1250 RPM at 600 Vdc, with the following
specifications:
   •    Armature                                0.64 Ohms ± 5% at 25°
   •    Shunt Field (total four coils)          1180 Ohms ± 5% at 25°
   •    Series Field (total four coils)         0.05 Ohms ± 5% at 25°
   •    Commutating Field (total four coils)    0.22 Ohms ± 5% at 25°
   •    Insulation Class                        Class “H”
   •    MP Gap                                  .075”
   •    IP Gap                                  .055”
The armature shall be reconditioned, including cleaning and inspection/testing for
grounding, shorts, hot-spots and damage, and shall be repaired or rewound, as
required. The commutator shall be resurfaced if smutting, grooving, threading,
etching or burning is evident. If the reconditioning requires removal of commutator
metal to the extent that the slot depth is less than 1/64”, the commutator shall be
undercut to 1/16” ± 1/64”. Reconditioned armatures shall be reinsulated with a
suitable varnish and process. If an armature requires rewinding and/or a new
commutator, the work shall be performed by an approved armature repair facility
according to manufacturers’ specifications.
The motor case shall be reconditioned, including cleaning and inspection/testing for
grounding, shorts, hot-spots and damage to all field coils, jumpers and motor leads.
Field coils that do not meet the manufacturers’ specifications shall be renewed and
the motor case reinsulated with a suitable varnish and process. Motor brush holders
shall be inspected for burning or damage, and renewed if required. All motor
bearings and brushes shall be renewed.
Motor straddle support mounting bolts shall be tightened to 70 lb.-ft. with dry
threads.

8.4.4      Motor Control Resistor Panel Assembly

The motor control resistor panel assembly is mounted to the motor support frame
assembly adjacent to the compressor motor. The resistors shall be reconditioned,
including cleaning, inspection and testing. Resistors that are burnt damaged or out
of tolerance shall be renewed. The resistor frame, jumpers between resistors and
wiring to the motor junction box shall be reconditioned.
Cables to the resistor panel are chaffing causing ground faults. The cables shall be
renewed and protected against chaffing.
Motor control resistor specifications:
   •    Compressor motor starting resistor              6.6 ohms
   •    Compressor buffer resistors                     2 ohms


Issue Date: 3/28/05                       8-7
IFB 4-002 TECHNICAL SPECIFICATION                                             8 – HVAC


8.4.5      Compressor/Compressor Motor Flexible Coupling

The flexible coupling (Safety P/N S-4709) between the compressor motor and the
compressor shall be reconditioned. Damaged or worn couplings shall be renewed.
The reconditioned/renewed coupling shall be installed and the compressor and
compressor motor aligned in accordance with manufacturers’ instructions.

8.4.6      Condenser Coil

The condenser coil shall be reconditioned. Clean, inspect and pressure test the coil.
Repair any leaks and straighten any bent fins. Use a manufacturers’ approved silver
solder for any repairs.

8.4.7      Liquid Receiver Tank and Refrigerant Lines

Purge/clean the receiver tank and all refrigerant lines. Pressure test and check for
leaks. Use a manufacturers’ approved silver solder for any repairs.
Inspect the liquid receiver tank sight glasses and renew any that are cracked,
damaged or clouded. Recondition the receiver tank shut-off valves with new seal
rings (Safety P/N T-16824-3). Renew damaged shut-off valves.
Renew the vibration eliminators (flexible tube connectors) using manufacturers’
approved silver solder.
The check valve (Safety P/N T-14691-2) is located in the discharge line between the
compressor and the condenser coil.          Recondition the check valve using
manufacturer’s procedures.
Inspect the refrigerant line insulation for temperature, vibration and corrosion
protection. Renew damaged insulation as required.

8.4.8      Filter Drier and Moisture Indicator

Renew the filter drier core assembly (Safety P/N T-9973) including all related
gaskets and hardware.
Clean and inspect the moisture indicator. Renew if damaged, cloudy or inoperable.

8.4.9      Evaporator Coil Assembly

The evaporator coil assembly consists of the evaporator coil, expansion valves (2),
line and modulation control valves and a liquid line strainer assembly. The
evaporator coil assembly is located overhead in the center of the car.
The evaporator coil shall be reconditioned. Clean, inspect and pressure test the coil.
Repair any leaks and straighten any bent fins. Use a manufacturers’ approved silver
solder for any repairs. Note that there may be two types of evaporator coils in
service, either a Safety P/N B-5300-1 or a B-5825-1.



Issue Date: 3/28/05                    8-8
IFB 4-002 TECHNICAL SPECIFICATION                                              8 – HVAC


Clean and inspect the evaporator coil condensate drain pan and drainage tubes for
damage or leakage. Repair any leaks and insure that the drain tubes are clear for
proper drainage. Renew any damaged drain pan insulation.
Renew the expansion valves. Although the new expansion valves should be preset
at the factory for 11°F operating superheat, they shall be checked for proper
adjustment.
Recondition the line and modulation control valves. The line and modulation control
solenoid valves are located in the liquid refrigerant line downstream of the strainer.
Units may have either the Safety P/N S-9196 type valve or the newer S-11841 type
valve in accordance with the type of evaporator unit (refer to Figure 8.4-1). Note that
parts may not be exchanged between the two valve types.
                                                  Complete
 Evaporator Unit                                                   Replacement Coil &
                          Valve Type          Replacement Valve
     Type                                                          Housing Assy. P/N
                                                Part Number
                      Line Solenoid               S-9196-19            T-20336-19
     B-5300-1
                      Modulation Solenoid         S-9196-20            T-20336-20
                      Line Solenoid               S-11841-1             S-11356-3
     B-5825-1
                      Modulation Solenoid         S-11841-2             S-11356-4


   Figure 8.4-1 – Line and Modulation Solenoid Valve ‘Safety’ Part Numbers
Recondition the liquid line strainer assembly (Safety P/N T-15531), located in the
liquid refrigerant line immediately ahead of the evaporator coil piping. Renew the
#80 mesh screen cartridge (Safety P/N T-15532-1) and renew the sealing gasket
(Safety P/N T-15532-2).
Renew all air flow switches.

8.4.10     Compressor-Condenser Assembly Support Frame

Modify the compressor-condenser assembly support frame to provide for easier
removal of the A/C Compressor. Review the proposed design with DTC personnel
for approval.
Clean and inspect the remaining portion of the frame assembly for cracks and weld
repair as required. The entire frame shall be primed and painted black in
accordance with Section 16. Renew all rubber support frame resilient mounts and
torque the through bolts to 45 lb.-ft.

8.4.11     Evaporator Blower Motor Assembly

The evaporator blower motor assembly shall be removed from the car for
reconditioning.



Issue Date: 3/28/05                         8-9
IFB 4-002 TECHNICAL SPECIFICATION                                               8 – HVAC


The existing 600 VDC brush evaporator motor shall be replaced with an
electronically commutated brushless DC motor similar to AMETEK Rotron motor
527346000 and external electronic drive 522210000 or approved equal. The motor
module combination shall be capable of delivering a minimum of 1.2 HP at 1900
RPM, and shall be powered from the car’s 37.5 Vdc low voltage inverter system.
The motor shall be designed to operate for a minimum of 60,000 hours of continuous
duty at its rated performance point without maintenance.
Recondition the blower fan housing and frame assembly. Repair or renew bent or
damaged fan wheel assemblies, fan housings and assembly frame. Renew the
evaporator blower assembly isolation mounts and attaching hardware.
The new electronic control module shall be mounted overhead near the evaporator
blower motor assembly, but shall not impede access to the door operator, lighting
fixtures, evaporator blower motor assembly or other car components requiring
routine maintenance. The mounting location shall be approved by DTC.

8.4.12     System Evacuation and Charging

Upon completion of all component work, evacuate the system according to
manufacturers’ procedures. Simultaneously evacuate the high and low side of the
system to 300 microns. The evacuation is acceptable if the vacuum needle does not
rise above 200 microns after the pump has been off for 30 minutes.
After successful evacuation, recharge the system with Refrigerant 22 according to
manufacturers’ procedures.
Prior to initial system startup, install a 325 mesh (44 micron) screen cartridge (Safety
P/N T-16454) in the liquid line strainer assembly to clean the system during the initial
6-10 hours of operation, and then replace with the standard #80 mesh screen
cartridge as described in 8.4.9.

8.5      HVAC CONTROLS

The HVAC controls are located both within the car and under the car as part of the
Compressor-Condenser Assembly. The HVAC Controls shall be reconditioned.

8.5.1      Refrigeration Controls Assembly

The refrigeration controls assembly (Safety P/N B-5388-1) is located on the
compressor-condenser frame.        All controls shall be reconditioned per the
manufacturers’ procedures, including, but not limited to, the following work:
Clean, inspect and test the manual selector switch. Renew the service valves.
Clean, inspect and test the high pressure, low pressure and pressure modulation
control switches according to the settings in Figure 8.5-1. As the switches are
neither adjustable nor field serviceable, renew any switches that do not meet
specifications.
All low voltage wiring, flexible conduits and connections shall be renewed.

Issue Date: 3/28/05                     8-10
IFB 4-002 TECHNICAL SPECIFICATION                                                 8 – HVAC




   Pressure Switch                      Actuation Pressure (psig)   De-Actuation Pressure
                           Safety P/N
        Type                                 Contacts Open          (psig) – Contacts Close
                                             2935 ± 69 KPa              22208± 69 KPa
  High Pressure (HP)         T-17124
                                             (425 ± 10 psig)            (320 ± 10 psig)
                                              138 ± 27 KPa               241 ± 27 KPa
  Low Pressure (LP)         T-19682
                                                 (20 ± 4 psig)           (35 ± 4 psig)

 Pressure Modulation                         2760 ± 48 KPa              2277 ± 69 KPa
                            T-15648
    Control (MPS)                             (400 ± 7 psig)            (330 ± 10 psig)


                      Figure 8.5-1 – Pressure Control Switch Settings

8.5.2      HVAC Motor and Temperature Control Panel Assembly

The HVAC Motor and Temperature Control Panel Assembly is mounted within the
equipment locker inside the car. This assembly consists of a high voltage panel, a
low voltage panel and a fuse panel. All HVAC Controls components shall be
reconditioned or renewed as follows:
The HVAC high voltage panel shall be cleaned, inspected and reconditioned. All
power contactor assemblies shall be renewed. All contact tips on low voltage
contactors shall be renewed. All relays are to be renewed.
The HVAC low voltage panel shall be cleaned, inspected and reconditioned. The
Fault Logic, TDR/Power Supply, Comparator and Relay Boards shall be tested and
repaired or renewed if defective. All relays and indicator lamps shall be renewed.
The HVAC fuse panel shall be cleaned, inspected and reconditioned in accordance
with Section 11.4.

8.5.3      HVAC Thermostats

HVAC system thermostats are located throughout the car and shall be cleaned,
tested, calibrated and renewed if defective. They are located as follows:
   •    Two solid state (Linister) Temperature Sensors (Safety P/N S-8438-5) are
        located in the recirculated air duct.
   •    The Layover Heat Thermostat is mounted under a seat.
   •    The Threshold Heat Thermostat is located in the outside air entry duct to the
        car.




Issue Date: 3/28/05                       8-11
IFB 4-002 TECHNICAL SPECIFICATION                                            8 – HVAC


8.5.4      Control Modification

The control system is currently designed to cycle the refrigeration compressor “ON”,
under all ambient temperature conditions, in response to a VOBC command to verify
the functionality of the HVAC system. A failure code is generated when the
compressor fails to start when commanded.
The HVAC control system shall be redesigned to inhibit the compressor from starting
whenever the ambient temperature is at or below 40oF. The redesign shall also
inhibit the generation of the corresponding failure codes
                                  End of Section




Issue Date: 3/28/05                   8-12
IFB 4-002 TECHNICAL SPECIFICATION                                             9 - LIGHTING



SECTION 9             LIGHTING
9.1     GENERAL

All interior light fixtures were originally supplied by Luminator. All interior and exterior
lights are powered from the low voltage, 37.5 VDC, system.

9.2     INTERIOR FLUORESCENT LIGHTING

The passenger area of the vehicle is illuminated by two continuous rows of fluorescent
fixtures, located at the juncture of the vehicle side walls and ceiling. The system
comprises 11 fluorescent fixture housings with lenses, 9 inverter ballasts, and 18
(eighteen) 48-inch fluorescent tube lamps.

9.2.1      Fixtures

All interior florescent light fixtures shall be replaced. New light fixtures shall be secure,
rattle free and vandal resistant. Fluorescent tubes and ballasts shall be inaccessible to
passengers. Diffusers shall be of a shatterproof material that conforms to the
requirements of Chapter 5, Fixed Guideway Transit Systems, NFPA 130, 2000. Details
of the proposed new lighting system shall be submitted to DTC for review and
acceptance.
Lighting fixtures shall be designed to allow the insertion of semi-transparent signs. The
fixtures shall provide back-lighting for the signs.

9.2.2      Lighting Levels

Under non-emergency lighting operating conditions, interior lighting levels shall be a
minimum of 54 lux (5 foot candles) measured at the vehicle floor, including all
doorways, and when the vehicle is stopped in the station, 215 lux (20 foot candles)
when measured 76 cm (30 inches) above the vehicle floor. Lighting shall be of a
consistent level.
Under emergency lighting conditions, the system shall provide a minimum of 54 lux (5
foot candles) measured in the immediate area of the doors for a minimum time period of
60 minutes (or time as determined by DTC to allow for safe evacuation of passengers).
In order to provide this minimum emergency illumination time, it will be permissible to
incorporate a “load-shed” of non-emergency lights upon loss of power for a
predetermined amount of time.
Lighting levels shall be sufficiently bright when operating at a minimum 35 vdc to meet
the minimum levels specified above with 50% of the lens covered with semi-transparent
signage.




Issue Date: 3/28/05                      9-1
IFB 4-002 TECHNICAL SPECIFICATION                                          9 - LIGHTING


9.2.3      Ballasts

All ballasts shall be replaced with new, electronic inverter ballasts, as approved by DTC.
DTC currently uses the Bodine 38TR40B ballast, which will be considered acceptable if
it meets the lighting levels of 9.2.2 with the fixtures and lamps supplied by the
Contractor. The Contractor shall coordinate the ballast with the other car electronics to
prevent any interference, adding filtering if required.

9.2.4      Lamps

All lamps shall be new T8 SP35 type, or as approved by DTC. All fluorescent lamps
should be of the same size to the extent possible, preferably 4 feet.

9.2.5      Wiring

All wire nuts and splice connections shall be removed. Car wiring shall be rearranged to
terminate at new terminal blocks, mounted so as to provide neat and secure routing of
the wires. Relocate wiring as necessary so it is not visible through the lens.

9.3     EQUIPMENT COMPARTMENT LIGHTING

Equipment compartment lighting consists of four ceiling-mounted incandescent dome
lamps, one per equipment compartment. Each fixture, Gulton P/N 01037773-005
houses one 20W incandescent lamp behind a clear lens. These lamps are illuminated
whenever their respective compartment doors are opened and automatically extinguish
when their doors are closed, by means of a door-operated control switch in each
compartment doorway.
All fixtures shall be reconditioned or renewed. Renew all lamps, gaskets, seals, lenses
and fasteners.
All door control switches shall be renewed.

9.4     PASSAGEWAY LIGHTING

The passageway lighting consists of two ceiling-mounted incandescent dome lamps,
one per passageway. Each fixture, Gulton P/N SD-0104804-001 houses two 20W
incandescent lamps behind a clear lens.
All fixtures shall be reconditioned or renewed. Renew all lamps, gaskets, seals, lenses
and fasteners.

9.5     HEADLIGHTS

Each vehicle has one pair of headlights on the front and one pair on the rear. Each
fixture Gulton P/N SD-0103730 houses a 60 W sealed beam lamp
Headlight fixtures shall be replaced with dual-beam headlight fixtures using dual-beam
60/80 W lamps operating from 28 vdc. Appropriate dropping resistors shall be installed.


Issue Date: 3/28/05                     9-2
IFB 4-002 TECHNICAL SPECIFICATION                                        9 - LIGHTING


The headlights shall automatically operate on low beams when the vehicle is the lead
car in a train operating in an un-manned mode. The Headlights shall provide low-beam
illumination for forward visibility of at least 0.5 foot-candles at 33 feet.
OFF/LOW/HI beam switches shall be installed in each hostler The headlight fixtures
shall be replaced with dual-beam headlight fixtures using dual-beam 60/80 W lamps
operating from 28 vdc. Appropriate dropping resistors shall be installed. A Hi/Low beam
switch shall be installed on each hostler panel.
The headlights shall automatically operate on low beams when the vehicle is the lead
car in a train operating in an un-manned mode.
OFF/LOW/HI beam switches shall be installed in eash hostler station to allow an
operator to control the headlights when the train is operated in the manual mode.
The design of the Hi/Low beam headlights shall be subject to DCT review and approval.

9.6    MARKER LIGHTS

Each vehicle has one pair of marker lights on the front and one pair on the rear. Each
marker light fixture Gulton P/N SD-0103773-001 houses a 20 W incandescent lamp, GE
S8-CM8-95 behind a red lens.
All marker light fixtures shall be reconditioned and modified to accept LED clusters or
replaced with fixtures accepting LED clusters.
The Contractor shall replace all S8-CM8-95 lamps with RED LED cluster lamps, railroad
type. The Contractor shall prepare a demonstration of the proposed lamp and lens for
DTC acceptance before ordering for the fleet.

9.7    INDICATOR LIGHTS

Each vehicle has a total of four indicator lights, a door status indicator and an
equipment fault indicator on each side of the vehicle just behind the front end cap.
The door status indicator fixture, Gulton P/N SD-0104312-001, contains a 20 W
incandescent lamp, GE S8-CM8-95, behind a red lens.
The equipment fault indicator fixture, Gulton P/N SD-0104312-002 contains a 20 W
incandescent lamp, GE S8-CM8-95, behind an amber lens.
All marker light fixtures shall be reconditioned and modified to accept LED clusters or
replaced with fixtures accepting LED clusters.
The Contractor shall replace all S8-CM8-95 lamps with LED cluster lamps, railroad type.
Colored LED lamps shall be used. The Contractor shall prepare a demonstration of the
proposed lamps and lenses for DTC acceptance before ordering for the fleet.




Issue Date: 3/28/05                   9-3
IFB 4-002 TECHNICAL SPECIFICATION                                              9 - LIGHTING


9.8    BACK LIGHT SIGNS

As an option, the Contractor shall install four (4) back-light sign holders, one on each
end bulkhead wall. The sign holder shall be back-light with florescent lighting. Lamp and
ballast types shall be consistent with overhead lighting previously specified. It is
recognized that lamp lengths will differ.
The design shall be submitted for DTC review and approval.

9.9    TESTING

All lights shall be verified for proper operation and lighting levels. Interior lighting levels
shall be demonstrated to meet the requirements of Section 9.2.2. Headlights shall be
aimed.
                                      End of Section




Issue Date: 3/28/05                       9-4
IFB 4-002 TECHNICAL SPECIFICATION                                    10 – PROPULSION



SECTION 10            PROPULSION
10.1     GENERAL

The propulsion system is composed of two truck-mounted Linear Induction Motor (LIM)
assemblies (one per truck), two Power Conversion Units (PCU’s) and one diode and
capacitor panel. This equipment was originally supplied by GEC Canada Ltd.
The system receives 600 Vdc from the wayside power rail and converts it into three-
phase AC power to drive the linear induction motors. The PCU processes thrust
demand signals from the VOBC system, to provide the appropriate frequency, current
and phase sequence input to the LIM. The LIMs produce electromagnetic force reacting
against induced current flow in the reaction rail to develop forward or reverse thrust to
produce vehicle motion.

10.2     LINEAR INDUCTION MOTORS

Characteristics of the linear induction motor:
   •     Input Voltage……………………………………………………                           410 Vac rms
   •     Input Current……………………………………………………                           0 – 485 amps rms
   •     Frequency………………………………………………………                              0-60 Hz
   •     Number of poles……………………………………………….                          6
   •     Number of phases……………………………………………..                         3
   •     Continuous current rating.............…………………………...         350 amps rms
   •     Continuous kVA rating…………………………………………                       250 kVA
   •     Electrical Connection…………………………………………..                     STAR
   •     Insulation………………………………………………………..                           Class H

All motors shall be completely reconditioned.

10.2.1     Windings

The LIM winding consists of a series of 72 coils made from copper strips and placed in
slots, arranged to form a conventional three-phase, six pole series motor internally star-
connected. The windings are impregnated with Class H insulation material.
The coils shall be cleaned, dipped, baked and tested. LIM’s were repaired and
overhauled in 2002/2003 as part of the truck overhaul program..
The 80 fiberglass wedges installed on top of the windings shall also be reconditioned.




Issue Date: 3/28/05                     10-1
IFB 4-002 TECHNICAL SPECIFICATION                                    10 – PROPULSION


10.2.2     Laminated Core

The core consists of side-by-side insulated iron laminations with staggered joints,
secured at 27 locations, sandwiched between the side members of the support
structure.
Recondition the core per OEM instructions.
The two fiberglass skids, provided on the LIM structure to protect the core from shorting,
shall be completely reconditioned.

10.2.3     Structure and Mounting

The LIM vertical and longitudinal thrust support members are made from cast steel. A
set of twelve links attaches to eight mounting brackets on the LIM structure to mount the
LIM to the truck.
Each link shall be reconditioned. All bearings, bushings and fasteners shall be
renewed. All other miscellaneous components used in the mounting and adjustment of
the LIM shall be reconditioned.
The structure, including the LIM winding slots, shall be completely reconditioned.
Upon reinstallation of the overhauled LIM, adjustments will be made as required to
provide the proper height and position of the motor with respect to the reaction rail.

10.2.4     Cooling Fan Assemblies

Each LIM is forced-air cooled by 10 axial fans, four on each top side of the LIM
assembly and two in the top center portion of the assembly. These fans are powered
by 27.5 VAC, 60 Hz, 3-phase voltage provided by two DC/AC fan inverters, one per
LIM.
The covers and brackets shall be reconditioned. All fasteners and gaskets shall be
renewed. Renew the connectors.
All 10 cooling fans, ROTRON P/N – 2577SF, shall be renewed.

10.2.5     Temperature Sensors

Two Klixon temperature sensors are incorporated into each LIM, on the winding
knuckles of coil No. 69 (130ºC sensor) and coil No. 70 (110ºC sensor). The sensors
shall be renewed, OEM P/N’s – Klixon 9700K11-33 and 9700K36-11.
The LIM cooling shroud shall be modified to allow temperature sensors to be renewed
without dismounting the LIM. The design is subject to DTC review and approval.

10.2.6     Power Connectors

Renew all power connectors to the LIMs.




Issue Date: 3/28/05                    10-2
IFB 4-002 TECHNICAL SPECIFICATION                                  10 – PROPULSION


10.2.7     Scraper Blades, Clamp Bars and Skid Plates

Renew any damaged or excessively worn scraper blade, clamp bars or skid plates.

10.3     POWER CONVERSION UNITS (PCU’S)

Each power conversion unit, One per LIM, consists of a logic control bin, an inverter
pannier and one positive and negative input filter reactor.

10.3.1     Logic Control Bin

The two logic control bins, one per LIM, are installed under the mid-left-hand passenger
compartment seats. Each bin contains 9 control modules manufactured by GEC
Alstom. The modules are designated PCO885 through PCO893.
The boxes and rack units shall be reconditioned.
All control modules and the mother board shall be reconditioned. The modules shall be
upgraded to include advanced diagnostics and fault-free service with the newer GTO
FIN inverter modules
Verify that all PCO8893 printed circuit boards have been upgraded to Revision 3 to
prevent ground faults when used with newer GTO FIN inverter modules.

10.3.2     Inverter Pannier

Each inverter pannier is rated at 340 kVA. The two inverter pannier assemblies are
installed on the underframe of the vehicle, one on each side between the trucks.
The boxes, covers and fins shall be reconditioned, including replacement of all seals,
gaskets and fasteners.
The cars currently run with a mix of older power transistor-style FIN inverter modules
and newer GTO FIN inverter modules. As part of this overhaul, all older-style modules
shall be replaced with the newer GTO style and the system tested and modified as
required to run properly with the newer-style GTO modules without recurring fault
codes. GTO FIN replacement inverter modules will be free issued by DTC.
Renew all moving parts of the D.C. circuit breaker (DCB1).
Renew the capacitor bank assemblies (C1) and the associated protection diodes (D1).
DTC will free issue the capacitor assemblies.
Renew thermostats 26T1 and 26T2.
Renew all thyristors.
The housing and all other components, including resistors, capacitors, reactors,
contactors, breakers, diodes, transformers, etc., within the pannier inverter shall be
reconditioned.




Issue Date: 3/28/05                   10-3
IFB 4-002 TECHNICAL SPECIFICATION                                      10 – PROPULSION


10.3.3     Auxiliary Power Supply (APS)

The auxiliary power supply, rated at 950 watts nominal, comprises a 48 volt step-up
chopper powered from the 37.5 volt battery voltage and a 25 KHz + 24 Volt Inverter
powered from the 48 volt chopper. These provide control power to the inverter portion
of the PCU.
Renew the electrolytic capacitors C1, C3 and C4 (GEC P/N – CE210KM and
CE17K5M).
Recondition the mini-bin and all four plug-in modules. Upgrade as required to allow
fault-free service with the newer GTO FIN inverter modules (See sections 10.3.1 and
10.3.2).
Thyristors shall be renewed. The housing and all other components, including resistors,
capacitors, reactors, contactors, breakers, diodes, transformers, etc., within the auxiliary
power supply shall be reconditioned.

10.3.4     Input Filter Reactors

Two filter reactors, OEM P/N – GEC 27X121, are provided for each PCU to protect the
PCU from line voltage spikes and for ripple current control. The reactors are mounted
on the vehicle underframe, between the two inverter panniers. These reactors are
protected by bottom and end reactor mesh covers.
Recondition the reactors (clean, check resistance, bake dry, dip and bake, retest).
Recondition the mesh covers. Renew all fasteners.

10.4     DC/AC INVERTERS

Cooling fans are powered by 27.5 VAC, 60 Hz, 3-phase voltage provided by DC/AC
inverters located in the rear equipment locker, refer to Section 11.

10.5     DIODE AND CAPACITOR PANELS

The diode and capacitor panel is located on the rear right-hand compartment bulkhead,
and contains four capacitors and four diode rectifiers to filter out any spikes in the
control voltage to the PCU.
This panel shall be completely reconditioned. All filter capacitors and suppression
modules shall be renewed. All fasteners shall be renewed.

10.6     TESTING

10.6.1     Continuity and Insulation Resistance

All wiring shall be tested for continuity after all equipment has been reconditioned and
reinstalled. All wiring shall be megger and hi-pot tested per APTA Std. SS-E-001-98.
Any wire that fails any of these tests shall be renewed.



Issue Date: 3/28/05                     10-4
IFB 4-002 TECHNICAL SPECIFICATION                                     10 – PROPULSION


10.6.2     Functional Testing

All components shall be tested to the extent possible in a bench test set-up as part of
the reconditioning process.        When the system has been reassembled after
refurbishment, a complete functional and performance test shall be performed on each
vehicle. These tests shall include verification of response to trainlines, indicators, test
points, acceleration, deceleration, jerk control, etc.



                                     End of Section




Issue Date: 3/28/05                     10-5
IFB 4-002 TECHNICAL SPECIFICATION                   10 – PROPULSION




                         Intentionally Left Blanl




Issue Date: 3/28/05            10-6
IFB 4-002 TECHNICAL SPECIFICATION                         11 - POWER DISTRIBUTION



SECTION 11            POWER DISTRIBUTION
11.1   GENERAL

The electrical system derives its primary 600-Vdc from the wayside power rails via
the power collector assemblies mounted on the sides of the trucks, or from shop
power. The primary 600-Vdc buss is routed through junction boxes into the shop
power switch assembly for distribution to the propulsion system, HVAC system and
the DC/DC Converter.
The DC/DC converter, originally provided by Stone Safety Corporation, converts
600-Vdc primary electrical power to 37.5-Vdc power for use by the VOBC, control
circuits, track brakes, charging the storage battery and other equipment monitoring
and auxiliary loads. Stone Safety converters are scheduled to be replaced in 2005
under a separate Contract. DTC will free issued new DC/DC converters to replace
any remaining Stone Safety converters.
Storage batteries are sized to provide 30 minutes of emergency power.

11.2   POWER COLLECTORS

All power collector assemblies shall be removed from the trucks.        The collector
assemblies shall be cleaned, inspected, reconditioned and tested.
Reconditioning shall include renewal of worn or damaged components and the
installation of new traction spring kits. Fuses, braided copper shunts and contact
shoes shall be renewed.
Power collector assemblies shall be installed with new insulators and fasteners.
Warning Labels shall be cleaned and reused, if clearly legible, or renewed if missing
or damaged.

11.3   SHOP POWER SWITCH

The Shop Power Switch (SPS) is a three-position isolating knife switch designed to
isolate 600-Vdc primary power from the car or to apply primary power either through
a shop receptacle for maintenance or from the power collectors for normal operation.
The SPS shall be completely disassembled to repair broken enclosure welds.
Welded repairs shall be thoroughly cleaned and primed to protect exposed metal
surfaces.
Damaged and missing components shall be renewed. Gaskets and seals shall be
renewed. Latches shall be repaired or renewed. New cover fasteners (one type)
shall be installed.
Fuses shall be renewed.
Missing or illegible terminal board markers shall be renewed.



Issue Date: 3/28/05                    11-1
IFB 4-002 TECHNICAL SPECIFICATION                          11 - POWER DISTRIBUTION


Interior surfaces shall be powder coated or primed and painted white with a white
insulating “Glyptol” paint. Exterior surfaces shall be primed and painted in
accordance with Section 16.

11.4   HV FUSE PANEL (HVAC)

The HV Fuse panel, located in the RH front equipment compartment, distributes
primary power to the HVAC system and monitors the level of the primary power.
The HV Fuse Panel shall be cleaned, inspected and reconditioned.            Damaged
components shall be renewed. All fuses shall be renewed.
The Power Relay Sensing Board, PSR, shall be tested, repaired and recalibrated.

11.5   DC/DC CONVERTER

The DC/DC Converter converts 600 Vdc, primary electrical power, to a nominal 37.5
Vdc, auxiliary electrical power. The DC/DC Converter interfaces with the VOBC for
fault detection and performance monitoring.
The Contractor shall verify that the Stone Safety converter has been replaced. The
Contractor shall replace any remaining Stone Safety converters with a new DC/DC
converter free issued by DTC.
The Contractor shall test the DC/DC converters, other than Stone Safety converters,
to OEM specifications to ensure functionality. As part of the functional test, the
Contractor shall perform all necessary adjustments.

11.6   BATTERY

Car batteries were replaced in 1997 with a 26-cell NiCd Battery, Model FNC KFMP,
as manufactured by Hoppecke. Battery capacity is 100 amp-hours at five-hour
rating.
The batteries shall be removed from the car, cleaned, inspected and tested for
capacity in accordance with OEM instructions. Damaged or degraded jumper cables
and fasteners shall be renewed.
Each battery cell shall be deep-cycle tested. Specific gravity of the electrolyte shall
be measured and recorded at the onset of the deep-cycle testing and at the
conclusion of the tests. Each cell shall be topped off with new electrolytic fluid.
Water of any type shall not be used to top off the cells.
Terminal bolts shall be torqued in accordance with OEM recommendations.
Battery cells that fail to achieve 90%-rated capacity after deep-cycle testing shall be
subject to DTC disposition. Defective battery cells shall be renewed as an extra cost
item in accordance with the Terms and Conditions.




Issue Date: 3/28/05                    11-2
IFB 4-002 TECHNICAL SPECIFICATION                           11 - POWER DISTRIBUTION


11.7   BATTERY MONITOR AND CB PANEL

The cars are equipped with battery monitors, Techniserve AG Inc. P/N D0727 (121e-
683-504-003), latest revision. The battery monitor checks the state of charge of the
batteries at all times and controls the output level of the DC/DC converter for battery
charging and float modes of operation. In addition, the battery monitor provides
failure warnings to both the VOBC and health monitor system should an abnormal
condition occur.
The Battery Monitor shall be cleaned, inspected and tested and re-calibrated in
accordance with OEM instructions.
The battery monitor circuit breaker (CB) panel located adjacent to the battery box
shall be cleaned, inspected, tested and re-certified. The shunt shall be tested for
calibration and shall be replaced if out of tolerance by more than ±2% from nominal.

11.8   LV CB PANEL

Each vehicle is equipped with two low voltage circuit breaker panels located in the
right-rear equipment compartment.
The panels shall be cleaned, inspected and tested. All circuit breakers shall be
renewed, as identified in Tables 11.8-1 and 11.8-2.


            Circuit Breaker             Circuit Identification               Rating
                CB1-WH        Warning Horns                                    5A
                CB1-WD        Windshield Demister                             10A
                CB2-MB        Track Brake (RH Front)                          30A
                CB1-MB        Track Brake (LH Front)                          30A
                CB3-BC        DC/DC Converter                                  5A
                CB1-FD        Smoke Detector                                   5A
                CB4-MB        Track Brake (RH Rear)                           30A
                CB3-MB        Track Brake (LH Rear)                           30A
                CB2-LB        Interior Lights (RHS)                           15A
                CB1-LB        Interior Lights (Emergency)                     10A
                CB2-PP        LIM No. 1 Fans                                  15A
                CB1-PP        PCU No. 1                                       40A
                CB3-LB        Interior Lights (LHS)                           10A
                CB1-LA        Exterior Lights                                 15A
                CB4-PP        LIM No. 2 Fans                                  15A


Issue Date: 3/28/05                    11-3
IFB 4-002 TECHNICAL SPECIFICATION                            11 - POWER DISTRIBUTION


            Circuit Breaker                Circuit Identification            Rating
                CB3-PP         PCU No. 2                                       40A
                CB2-DB         Disc Brakes (Auxiliary Motor)                   20A
                CB1-DB         Disc Brakes (Primary Motor)                     20A
               CB2-ATC         ITU                                             20A
               CB1-ATC         VOBC                                            10A


                               Table 11.8-1 Top Panel


            Circuit Breaker                Circuit Identification            Rating
                CB1-HM         Health Monitor                                  5A
                CB2-BC         Test Receptacles                                20A
                CB2-CF         Coupler (Heads Heating)                         20A
                CB1-CF         Coupler (Power Supply)                          25A
                CB3-DC         Front Doors (Power Supply)                      15A
                CD2-DC         Door Indicator Lights                           5A
                CB1-DC         Rear Doors (Power Supply)                       15A
                CB1-HC         HVAC                                            15A
               CB1-WW          Windshield Wipers                               10A
                CB1-PA         Communications                                  15A


                              Table 11.8-2 Bottom Panel

11.9   LV RELAY PANEL

The low voltage relay panel located in the right-rear equipment compartment
contains plug-in relay and a flasher for control of low voltage systems and
subsystems. The panel shall be cleaned, inspected and reconditioned. All relays
shall be renewed. Missing parts and defective relay sockets shall be renewed.
The relay entire panel shall be tested.

11.10 HEALTH MONITOR

The Health monitor shall be inspected and tested.          All indicator lamps shall be
renewed. DIP switch settings shall be verified.



Issue Date: 3/28/05                       11-4
IFB 4-002 TECHNICAL SPECIFICATION                          11 - POWER DISTRIBUTION


11.11 DC/AC INVERTERS

There are three 500-watt inverters mounted on the rear LH compartment bulkhead.
The inverters operate from a 37.5-Vdc input and produce 27.5-Vac, 60-Hz, 3 Phase
ac voltage for cooling fans.


           Inverter         CB         Function
           INV1-PP       CB2-PP        Cooling Fans, LIM No. 1
           INV2-PP       CB4-PP        Cooling Fans, LIM No. 2
           INV1-HC       CB1-HC        Cooling Fans: VOBC
                                       Blower  Motors:     Floor      Heaters     and
                                       Emergency Ventilation


                       Table 11.11-1, Cooling Fan Inverters
The inverters shall be replaced. The new inverters shall have sufficient capacity for
the required loads on the vehicle. The new inverters shall be sealed and protected
from moisture. The inverters are mounted behind the nose access panel and are
subject to exposure to moisture. The design shall be submitted for DTC approval.
The original ROTRON Inverters are no longer available. The Van’s Electronic Ltd.
inverters, P/N VEL1882 and other supplier inverters have proved unreliable.

11.12 HV CABLES

Underfloor high voltage (600-Vdc) electrical cables and connectors shall be
inspected. All HV cleat blocks and cable supports shall be opened for cable
inspection. All cabling shall be tested for insulation integrity. Damaged, cut, spliced
or oil-soaked cables shall be renewed. Damaged or hardened (if neoprene) cleat
blocks shall be renewed. LIM connectors shall be renewed.

11.13 LV WIRING AND CABLES

All low voltage (37.5-Vdc and 27.5-Vac) wiring and cabling and associated
connectors shall be inspected. All LV wiring shall be tested for insulation integrity.
Damaged cables, wiring and connectors shall be renewed. Wiring with splice joints
shall be replaced. Quick disconnect connectors shall be utilized to the extent
possible.
Exterior LV underfloor connector cable assemblies between control compartments
and wire runs shall be renewed.
Cable connectors on equipment enclosures, conduits and wire runs shall be cleaned
and inspected. Damaged and defective connectors shall be renewed.



Issue Date: 3/28/05                    11-5
IFB 4-002 TECHNICAL SPECIFICATION                        11 - POWER DISTRIBUTION


All flexible conduits shall be cleaned and inspected. Damaged conduit shall be
renewed.

11.14 JUNCTION BOXES

All junction boxes shall be opened, cleaned and inspected.
Damaged wiring and terminal boards shall be renewed.
Missing covers, gaskets and securing cover fasteners shall be renewed. Latches
shall be renewed or repaired as required.


                                  End of Section




Issue Date: 3/28/05                   11-6
IFB 4-002 TECHNICAL SPECIFICATION                              12 – BRAKE EQUIPMENT



SECTION 12            BRAKE EQUIPMENT
12.1     GENERAL

The Brake System consists of disc brakes, dynamic brakes and track brakes
automatically controlled by the VOBC. A hostler stations located at each end of the
car permits manual control of the brakes. Manual cutout/release levers are located
at each end of the car to manually disable or release the disc brakes on a per truck
basis for maintenance or emergency conditions.
Primary brake effort is provided by dynamic braking supplemented by friction, disc
brakes. Overhaul of the dynamic brake system is part of Section 10, Propulsion.
Track brakes are utilized to provide supplemental brake effort in emergency
situations and hold the train stationary when stopped.
All of the existing equipment shall be retained, reconditioned, tested and re-qualified
for service.

12.2     FRICTION BRAKE SYSTEM

The friction brake system was provided by New York Air Brake, NYAB. The system
consists of four axle-mounted discs, one per axle, caliper assemblies with actuators
and a hydraulic pump with distribution manifold. The friction brake system is
automatically and manually controlled by the VOBC.
The actuators are spring applied and hydraulically released.

12.2.1     Caliper Assembly

 Recondition the four (4) calipers and two manual release mechanisms, by renewing
all bushings in levers and caliper assembly/housings, cables, sheave wheels, pins,
cotter keys, brake keys, caliper spring disks, hydraulic and grease fittings, hydraulic
seals and “O” rings, slack-adjusting/cut-out mechanism wearing components, brake
pads, brake pads retainers and wear plates. Clean and inspect levers and brake
rigging. Inspect and recondition brackets. Paint brake calipers and levers in
accordance with Section 16.
In General, all components including linkages for mechanical or hydraulic release of
brakes and application of spring brake shall be reconditioned to restore the brake
caliper assembly to meet original O.E.M. specifications and performance.
All reconditioned brake caliper assemblies shall be bench tested after overhaul for
adjustment and confirmation that all O.E.M. functions and performance are met.
The results of the bench testing, including but not limited to hydraulic pressure vs.
brake shoe force readings and manual cut-out functions shall be documented and
submitted as part of the Car History Book.




Issue Date: 3/28/05                     12-1
IFB 4-002 TECHNICAL SPECIFICATION                               12 – BRAKE EQUIPMENT


12.2.2     Controls and Pump

Remove and recondition the Motor Relay, Magnetic Valve Control Unit (MVCU),
Hydraulic Brake Control Unit (HBCU), Hydraulic Power Unit (HPU), and Brake
Control Electronics Unit (BCEU).          The reconditioning includes all internal
components of the above units, i.e., hydraulic pumps, and brake manifold shall be
reconditioned. This includes all filters & strainers (both high pressure and suction),
elastic seals and “O” rings, all check valves, all cutout cocks, all regulator valves, all
reducing valves, all release and apply solenoid valves, all high and low pressure
transducers, pressure switches, emergency brake valve, auxiliary release valve,
spring applied parking brake valve, hand valves, pressure limiting valves, motor for
hydraulic pump, pump low level switches and high level switches.
Replace the primary (40%) and secondary (100%) hydraulic pump motors with
brushless motors. The Contractor shall submit the design for the circuit, circuit
breakers, and wiring changes for DTC review and approval. Power and hydraulic
connections to the pump shall be with quick-disconnect connectors for ease of
maintenance.
The Brake Controller and all associated hydraulic and electrical controls at the
manual control station shall be reconditioned. This includes the Track Brake Relay
Panel, Circuit Breaker Panel, and Hostling Panel at each end of the car. All controls
- Emergency Stop and Master Control Handle (thrust lever) with Deadman relays -
shall be reconditioned and indicator lamps shall be renewed.

12.2.3     Hydraulic Piping and Hoses

Inspect and renew as needed, the hydraulic piping/tubing. These shall be inspected
and renewed if any are bent, dented, or worn. Replacement brake piping shall be
seamless 304 stainless steel tubing, MIL-T-8504. Test fittings found to be leaking
shall be renewed. All caps on test fittings shall be renewed. All piping clamps shall
be renewed. All damaged brackets shall be renewed. All hydraulic hoses shall be
renewed.
The hydraulic system shall be drained and cleaned. The system shall be refilled
with hydraulic fluid MIL-H-83282.
Quick disconnect fittings shall be applied to all hoses going to the pump and
calipers. Isolation valves shall be installed between the pump and each truck to shut
off the flow of oil in the event of a line break or rupture. The purpose of the valves is
to avoid “fanning” a fire with oil should an undercar fire occur and provide some
function for the brakes on the truck opposite the break.

12.2.4     Rotors and Hubs

Inspect disc brake rotors and hubs for thickness and surface defects. DTC will
provide a replacement wheel/axle assembly if a disc rotor cannot be resurfaced.
Resurface the disc rotors. Record the thickness of the rotors before and after
resurfacing.


Issue Date: 3/28/05                      12-2
IFB 4-002 TECHNICAL SPECIFICATION                         12 – BRAKE EQUIPMENT


12.3   TRACK BRAKE ASSEMBLIES

The track brake assemblies and truck junction boxes were reconditioned as part of
the truck overhaul in 2003. Track brake assemblies and junction boxes shall be
inspected, tested and repaired as necessary.
Recondition the Track Brake Control Panel board. Renew the relays and timers.

12.4   BRAKE INTERFACE ASSEMBLIES

The entire carbody mounted wiring interface for braking shall be inspected and
tested. The Contractor shall inspect and test the Junction boxes for Disk Brake
Control, Track Brake Control and Interface to dynamic brake controls with other
systems, including: Vehicle On Board Controls, Hostling Panel, Health Monitor, and
Circuit Breaker Panel. Damaged wiring and defective components shall be
renewed.


                                 End of Section




Issue Date: 3/28/05                  12-3
IFB 4-002 TECHNICAL SPECIFICATION                 12 – BRAKE EQUIPMENT




                       Intentionally Left Blank




Issue Date: 3/28/05            12-4
IFB 4-002 TECHNICAL SPECIFICATION                                          13 - TRUCKS



SECTION 13            TRUCKS
13.1   GENERAL SCOPE

Bombardier completed an overhaul of the Detroit APM Vehicle trucks in 2004. The
overhaul included a complete rebuild of the truck and bolsters assemblies. As part of
the overhaul, DTC installed refurbished track brake and current collector assemblies.
Excluded from the truck overhaul are refurbishment of wheel and axle assemblies,
truck mounted brake equipment and the linear induction motors.
The trucks are steerable with cast aluminum side and bolster frames. The trucks
utilize 18 inch wheels. The LIM’s are suspended below the truck assemblies.
Truck alignment is critical for the reduction of wheel wear, ride quality and the
reduction of wheel to rail noise.
The Truck overhaul as specified by this Contract is limited to the refurbishment of
truck mounted equipment.
The Contractor shall de-truck and re-truck each DPM vehicle as part of this Contract.
Each truck shall be cleaned and visually inspected.
Steering link brackets have been subject to cracking. All steering link brackets that
exhibit any signs of cracks on the end plates and around the doublers shall be
renewed.

13.2   SHIPPING AND RECEIVING OF DPM VEHICLES

The Contractor shall be responsible for dismounting and remounting DPM vehicles
onto the guide way rails. DPM trucks are extremely sensitive to misalignment. The
Contractor shall submit for DTC review and approve procedures for transferring
DPM vehicles from the guide way to transport vehicles and for securing the DPM
vehicle to the transport vehicle for shipment.

13.3   TRUCK AND BOLSTER OVERHAUL

The Contractor shall remove truck mounted equipment specified for refurbishment in
accordance with this specification. The Contractor shall then, as part of this
Contract, prepare for shipment to Bombardier those trucks and bolster assemblies
that still require overhaul. The Contractor shall coordinate shipping and receiving of
truck and bolster assemblies with Bombardier and DTC QA personnel. Shipping
costs for the truck assemblies to Bombardier are outside of this Contract.
At the issuance of this Technical Specification, six car sets of trucks have been
overhauled or are in-process. Since the overhaul is in progress, DTC will identify
vehicles with overhauled trucks at Contract Award.
The Contractor shall install all truck mounted equipment, after refurbishment, on
overhauled truck and bolster assemblies.



Issue Date: 3/28/05                    13-1
IFB 4-002 TECHNICAL SPECIFICATION                                        13 - TRUCKS


Truck assembly paint shall be touched up as required.
The Contractor shall verify and adjust the truck alignment once the vehicles are
retrucked. The truck alignment procedure shall be submitted for DTC review and
approval.

13.4   WHEEL AND AXLE ASSEMBLY

Wheels shall be machined to the current DTC wheel profile. The drawing will be
provided to the Contractor. Wheels that fail to meet minimum requirements shall be
renewed by Change Order. DTC may, at their option, free issue replacement
wheel/axle sets.
Brake discs and hubs shall be inspected and refurbished in accordance with Section
12.
Bearings shall be inspected in accordance with OEM procedures. Defective bearings
shall be replaced as an extra cost item.
Ground brush rings shall be inspected in accordance with OEM procedures and
resurfaced or renewed if beyond tolerance. Ground brush rings that must be
renewed will be an extra cost item.
Axles shall be inspected and DTC notified of damage or defects found in the axles.



                                  End of Section




Issue Date: 3/28/05                   13-2
IFB 4-002 TECHNICAL SPECIFICATION                            14 – COMMUNICATIONS



SECTION 14            COMMUNICATIONS
14.1   COMMUNICATION SYSTEM DESCRIPTION

The Vehicle Communication System (VCS) on the DPM vehicles provide all voice
and certain data communications between the Control Center and vehicles on the
guideway. The VCS system was manufactured by RMS Industrial Controls, Inc.
Data communications consist of vehicle radio control signals and Vehicle Health
Monitor data.
Voice functions consist of: a public address, controller to vehicle(s), local public
address from the train hostler auxiliary panels, two way voice communications
between the Control Center and passenger access panels, and door closure
warning. Two-way voice communications are fully duplexed, allowing simultaneous
conversation between the Control Center operator(s) and the person on the vehicle.
Vehicle radios operate under software control. An on-board microprocessor controls
all functions of the vehicle’s radio equipment. Certain functions such as hostler PA
announcements and door closure warnings are controlled directly by the onboard
microprocessor. Most radio functions are ultimately under supervisory control of the
RCC3 Control Center, located in the MCF building.
The VCS equipment located on each vehicle includes:
   •   1 Comsyst4 – V1A 900 MHz, 20W, full duplex FM radio (Rack A)
   •   1 Comsyst4 – V1B Controller, Audio PA and power converter (Rack B)
   •   1 Vehicle Voice Announcement Unit (VVAU)
   •   2 Passenger Access Panels (PAP)
   •   2 Hostlers Auxiliary Panels (HAP)
   •   6 Ceiling mounted P.A. speakers with matching transformers
   •   1 Low profile roof mounted UHF antenna
This equipment is interconnected via train wiring, which includes a P.A. trainline to
pass P.A. audio between vehicles in multi-car consists.
Also connected to the Rack B unit is a door closure warning tone generator,
provided by the VOBC, and the Vehicle Health Monitor Panel (HMP).

14.2   SCOPE OF VCS OVERHAUL

The Contractor shall recondition the Passenger Access Panels, and Hostler Auxiliary
Panels. The six passenger speakers shall be renewed. All VCS system
interconnection wiring shall be inspected, tested and repaired or renewed as
required.




Issue Date: 3/28/05                   14-1
IFB 4-002 TECHNICAL SPECIFICATION                            14 – COMMUNICATIONS


The 900 MHz Duplex radio and associated communications equipment in Rack A,
Rack B was renewed and upgraded in 2003/2004. The Contractor shall not be
responsible for reconditioning this equipment. The Contractor shall inspect and test
the entire VCS system including the Rack A, Rack B and VVAU equipment to
ensure proper operation and integrity of the entire vehicle communication system in
accordance with the procedures in the DPM Vehicle and Wayside Maintenance
Radio Manuals.

14.3   PASSENGER ACCESS PANELS

Passenger Access Panels (2) shall be reconditioned. Reconditioning of the PAP
(RMS P/N AX-Panel 1) shall include, but not be limited to renewal of the speaker
(RMS P/N Hx-448) and the push-to-talk switch lamp. The switch/lamp assembly
(RMS P/N’s SP-3SB1400-08, SP-3SB1400-2G and SP35B12180AC01) and the
dynamic omni-directional microphone (RMS P/N ZM-WM500) shall be cleaned and
tested. All PAP wiring and terminal strips shall be inspected and tested, and
renewed as necessary.
The PAP shall be functionally tested in accordance with OEM procedures.

14.4   HOSTLERS AUXILIARY PANELS

Hostlers Auxiliary Panels (2) shall be reconditioned. Reconditioning of the HAP
(RMS P/N AX-Panel 2) shall include, but not be limited to renewal of the push-to-talk
switch lamp. The switch/lamp assembly (RMS P/N’s SP-3SB1400-08, SP-3SB1400-
2G and SP35B12180AC01) and the dynamic omni-directional microphone (RMS
P/N ZM-WM500) shall be cleaned and tested. All HAP wiring and terminal strips
shall be inspected and tested, and renewed as required.
The HAP shall be functionally tested in accordance with OEM procedures.

14.5   CEILING MOUNTED PUBLIC ADDRESS SPEAKERS

All six (6) ceiling mounted public address speakers shall be renewed (RMS P/N HX-
603B/6FB). Each speaker is equipped with a 70V matching transformer.

14.6   ROOF MOUNTED ANTENNA

The low profile 900 MHz UHF roof mounted antenna shall be cleaned inspected and
tested.

14.7   ADA ELECTRONIC SIGNS

The VCS shall be upgraded, as an option, to include ADA compliant electronic signs
for station announcements and the display of emergency information. The sign
displays shall be control through the VCS.




Issue Date: 3/28/05                   14-2
IFB 4-002 TECHNICAL SPECIFICATION                              14 – COMMUNICATIONS


Signs shall not interfere in any manner with the Automatic Train Control System or
radio communications between on-board radios, handheld radios and Central
Control radios.

14.8   VCS TESTING

All VCS system jumper cables, connectors, terminal blocks and wiring shall be
inspected, tested and renewed, if required.
All existing VCS interfaces with other car or Control Center systems shall be
maintained and fully tested. This includes, but is not limited to the Health Monitoring
Panel, the Vehicle On-Board Computer, Door Closure Warning system, vehicle
signatures, the Automatic Train Control system, data and voice radio
communications and the Control Center.
The reconditioned VCS system shall be functionally tested in accordance with the
Contractor’s test plan.


                                   End of Section




Issue Date: 3/28/05                    14-3
IFB 4-002 TECHNICAL SPECIFICATION                 14 – COMMUNICATIONS




                       Intentionally Left Blank




Issue Date: 3/28/05            14-4
IFB 4-002 TECHNICAL SPECIFICATION                                            15 - VOBC



SECTION 15            VOBC
15.1   GENERAL SCOPE

Each DPM vehicle is equipped, with an Automatic Train Control (ATC) Vehicle-On-
Board Computer (VOBC) and associated, hostling panel, electronics, antennas,
tachometer generators and accelerometer. The VOBC in conjunction with wayside
ATC equipment automatically controls vehicle operation.
The VOBC is mounted in a 19 inch wide rack within the VOBC equipment
compartment inside of the car. The VOBC will be upgraded by separate Contract
after vehicle overhaul.
The work scope for VOBC rack mounted equipment, for the vehicle overhaul, shall
be limited to the removal of the VOBC equipment rack for refurbishment of the
equipment locker, reinstallation of the VOBC rack mounted equipment after locker
refurbishment and the functional test of the VOBC equipment following reinstallation.
Hostling panels shall be refurbished.
Antennas and tachometer generators shall be renewed.
Wiring and cabling shall be inspected, tested and renewed as specified herein.

15.2   VOBC EQUIPMENT LOCKER

The VOBC equipment rack shall be removed from the VOBC equipment locker to
facilitate cleaning, modifying, repair and refurbishing of the locker.
Ventilation fans shall be renewed.
Flooring and insulation shall be renewed as specified in Section 4.
VOBC equipment shall be reinstalled and tested after completion of locker overhaul.

15.3   VOBC EQUIPMENT CABLING

Carborne VOBC interface cabling and wiring shall be inspected and tested for
continuity and insulation integrity. Defective wiring and cabling shall be renewed.
Wiring and cabling between the VOBC equipment rack and car mounted terminal
boards shall be inspected and repaired to ensure the functionality of the VOBC.
Power cables shall be renewed.

15.4   HOSTLING PANEL AND PANEL ELECTRONICS

The Hostling Panel and Panel Electronics shall be refurbished. All switches,
indicators, capacitors and relays shall be renewed.




Issue Date: 3/28/05                     15-1
IFB 4-002 TECHNICAL SPECIFICATION                                            15 - VOBC


15.5   ANTENNA, TACHOMETERS AND ACCELEROMETER

Tachometers and associated cabling shall be renewed. The tachometers are
mounted on a bogie-mounted assembly. The existing housing assembly may be
utilized after refurbishment.
Four antennas, two receiver antennas and two transmit antennas, are mounted on
the underside of the vehicle. All four antennas and associated cabling shall be
renewed. The existing mounting arrangement may be utilized after refurbishment.
The accelerometer shall be tested and renewed by Change Order if defective. The
Accelerometer will be renewed with the VOBC upgrade.

15.6   VOBC TO VEHICLE INTERFACE MARSHALLING PANEL

Each vehicle has a marshalling panel which interfaces with the VOBC and vehicle
subsystems. The marshalling panel is contained in the VOBC equipment rack. The
vehicle interface marshalling panel includes filters to protect the VOBC from surges.
All filters shall be renewed and the marshalling panel reconditioned.

15.7   SOFTWARE UPGRADES

Not used.

15.8   DOCUMENTATION

Not used.

15.9   TESTING

The VOBC and interfaced systems shall be tested by the Contractor for functionality.
The Contractor shall prepare a testing plan in advance of testing for DTC approval.
The testing will include the following:
   •   Factory Functional Tests
   •   Post Installation Checkout (PICO)
   •   Commissioning Testing



                                    End of Section




Issue Date: 3/28/05                       15-2
IFB 4-002 TECHNICAL SPECIFICATION                         16 – PAINT AND GRAPHICS



SECTION 16            PAINT AND GRAPHICS
16.1   GENERAL

The Contractor shall repaint as required in accordance with current DTC paint scheme
drawings.
The Contractor shall use Akzo-Nobel brand paint. An equivalent paint brand compliant
with local painting codes may be used with prior DTC approval. The Contractor shall
submit sufficient information for DTC to determine equivalency. Paint shall be applied
following the preparation in accordance with to paint manufacturer recommendations.
All surfaces requiring paint shall be thoroughly cleaned, prepared, and primed prior to
applying finish coats of paint. Care shall be taken to ensure that all oily residues from
hydraulic fluid leaks are removed.

16.2   EXTERIOR

The DPM vehicle exteriors have been recently painted and detailed. The markings on
the vehicles are currently applied with paint.
Minor surface defects shall be repaired with an approved epoxy filler material and
ground and sanded smooth.
The exterior surface of the DPM vehicle shell including the roof, skirts and door panels
shall be primed and painted in accordance with DTC Drawing TBD.
       •   Overall Vehicle Basic Color: OFF-White 52-07-75
       •   Decorative Stripping: YELLOW PMS 109
       •   Decorative Stripping: DARK GREEN PMS 342
       •   DPM Symbol: DARK GREEN
       •   Vehicle Number: DARK GREEN

16.3   INTERIOR

Painted surfaces within the interior shall be repainted and detailed in accordance with
the existing colors, subject to DTC approval.

16.4   UNDERFLOOR

All underfloor equipment shall be removed to the extent possible and cleaned to remove
dirt and hydraulic residues. Electrical cabling and wiring, elastomeric components, and
friction surfaces shall be masked to prevent overspray. Metal exposed by repair and
inspection work shall be primed.
The under floor structure shall be painted black.




Issue Date: 3/28/05                    16-1
IFB 4-002 TECHNICAL SPECIFICATION                         16 – PAINT AND GRAPHICS



16.5   EQUIPMENT ENCLOSURES

The interior of new or replacement underfloor electrical equipment enclosures shall be
primed and painted with a white glyptol insulating paint. An insulating powder coating
may be applied as an alternative.

The interiors of existing underfloor equipment enclosures subject to overhaul or
refurbishment shall be cleaned and painted as required.

The exterior of all underfloor equipment enclosures shall be primed and painted black.

16.6   TRUCKS AND TRUCK MOUNTED EQUIPMENT

The trucks have recently been overhauled. The trucks shall be cleaned and the paint on
the trucks shall be touched up to achieve a coherent finish.

16.7   DECALS AND SIGNS

All original decals shall be renewed in kind unless otherwise specified. In general, all
original name plates are to be renewed. All letters and numbers shall be black
Helvetica Medium capitals unless otherwise noted. All art work shall be submitted for
DTC approval.
The following letters, numbers and logos as a minimum shall be positive printing on
0.002 minimum thickness vinyl film (3M Controltac 180 or similar) with repositionable
(low initial tact) permanent adhesive back, and with printing protected with clear Mylar
overlay. All letters, numbers, and logos shall be sealed after application with two coats
of clear sealer, overlapping all edges by 0.5" (12 mm).
       •   4 each Exterior “In Emergency Break Cover – Door”
       •   2 each, Interior “Vehicle Numbers”
       •   4 each Interior “No Smoking"
       •   2 each Interior “Access Seating”
       •   2 each interior “Emergency Assist Phone”
       •   4 each Interior “In Emergency”
       •   4 each interior “Do Not Block Doorway”
       •   4 each Interior “Priority Seating”
       •   8 each large Interior “Caution Do Not Lean On Doors”
       •   8 each small Interior “Caution Do Not Lean On Doors”
       •   2 each Interior “Emergency Exit”
       •   2 each Interior, foil covered “Emergency Exit”
       •   1 each Interior “Smoking/Food/Liquids Prohibited”
       •   2 each Interior “Flip Seat Latch”
       •   2 each interior, aluminum ad sign holders
       •   1 each interior “Fire Extinguished (Emergency Tools)”
       •   1 each interior “Alarm Will Sound”


Issue Date: 3/28/05                    16-2
IFB 4-002 TECHNICAL SPECIFICATION                              16 – PAINT AND GRAPHICS


Push-totalk signs shall be in Braille as well as in English.

16.8    BUILDER'S PLATE

Contractor shall supply and install one (1) builder's plate per vehicle.
Plate shall be 0.080" (2.0 mm) thick aluminum or stainless steel with 0.375" (9.5 mm)
incised letters filled with black paint, mounted with eight (8) tamper proof fasteners on
the inner face of the access door to the electric locker relay panel at a location
acceptable to DTC.
Plate shall include the following data:
    • Authority Logo
             o Name
             o Car Number
    • Original Builder
             o Name
             o Location
             o Date
             o Serial Number
    • Overhaul Contractor
             o Name
             o Location
             o Date
                                          End Section




Issue Date: 3/28/05                        16-3
IFB 4-002 TECHNICAL SPECIFICATION                  16 – PAINT AND GRAPHICS




                        Intentionally Left Blank




Issue Date: 3/28/05           16-4
IFB 4-002 TECHNICAL SPECIFICATION                                      17 – MISC.



SECTION 17            Miscellaneous
17.1   SMOKE ALARMS

There are two smoke/fire alarms in DPM vehicles. The smoke/fire alarms shall be
renewed.



                                End of Section




Issue Date: 3/28/05                   17-1
IFB 4-002 TECHNICAL SPECIFICATION                 17 – MISC.




                       Intentionally Left Blank




Issue Date: 3/28/05            17-2
IFB 4-002 TECHNICAL SPECIFICATION                               18 - DOCUMENTATION



SECTION 18            TECHNICAL PUBLICATIONS AND TRAINING
18.1     GENERAL SCOPE

The Contractor shall provide all required maintenance manuals, renewal parts
manuals, car history books, drawings and DTC staff training and associated training
materials required for operation and maintenance of the DPM vehicles.
The manuals shall consist of Operating Instruction Books, Maintenance Manuals
and Parts Manuals. The Manuals shall be complete in that they shall include all
information required to properly operate and maintain the cars without the need to
reference other information or documents not included with the manuals. Applicable
Contractor and Vendor/Sub-Contractor drawings and manuals shall be included.
The existing manuals shall be updated to the current “As-Overhauled” configuration
after overhaul and provided in both hard-copy and in electronic format.
The Contractor shall furnish hard copy and electronic format engineering copies of
the latest revision of all Contractor and Vendor/Sub-Contractor Drawings produced
for the “As-Overhauled” vehicle configuration.
As an option to the base price of this Contract, the Contractor shall provide services
to copy and convert all existing original UTDC and Vendor/Sub-Contractor drawings
for the DPM vehicles from a microfiche format to a CD-ROM format.
The Contractor shall develop and conduct training programs for the operation and
maintenance of the DPM vehicles in their “As Overhauled” state to DTC personnel.
The Contractor shall prepare all training manuals and materials required to conduct
the training programs. The training program shall address those systems that have
not previously been in service on the DPM vehicles.

18.2     MANUAL AND DRAWING REQUIREMENTS AND FORMAT

18.2.1     General Publications Requirements

There shall be three (3) comprehensive manuals: 1) Operating Instruction Manuals,
2) Maintenance Manuals, and 3) Parts Manuals. In addition, there shall be a
complete set of technical drawings produced that encompass all aspects of the car.
The format of the manuals shall follow the format of the existing manuals. DTC shall
provide a set, to the extent possible, of existing DPM vehicle manuals to the
successfully Bidder.
The manuals shall be logically organized with systems and elements considered in
descending order of importance. The manuals shall be complete, modern, authentic
and thoroughly organized with adequate cross references and Table of Contents.
The manuals shall not include extraneous material such as advertisements or
irrelevant information.




Issue Date: 3/28/05                    18-1
IFB 4-002 TECHNICAL SPECIFICATION                                 18 - DOCUMENTATION


The Manuals shall be complete in that they shall include all information required to
properly operate and maintain the cars without the need to reference other
information or documents not included with the manuals. Applicable Contractor and
Vendor/Sub-Contractor drawings and manuals shall be included.                Where
appropriate, the existing manuals shall be updated to the current “As-Overhauled”
configuration after overhaul.
All material shall be clearly reproducible by dry copying machines. This precludes
the use of halftone illustrations or photographs. Blueline drawings are not permitted
in the manuals.
All pages of manuals which are written pursuant to this Contract shall be prepared
using a computer-based text preparation and editing system such that:
   •   Revision of pages shall not require retyping of material which is unchanged.
   •   Changes relative to the version most recently submitted to DTC for review
       shall be highlighted by distinctive underlining, or by some distinctive indication
       in the margin.
   •   Every page indicates the date of its print-out, as well as its page number and
       the manual to which it belongs.
The final version of the all manuals shall be submitted in both hard copy (printed)
and in software (electronic) formats. The Contractor shall provide to DTC one copy
of the publishing software package used to produce the Maintenance Manuals,
Operating Instruction Books and Parts Manuals.

18.2.2 Manual Submittal and Review

Draft copies of manuals shall be submitted to DTC for approval of format and
content no later than four (4) weeks prior to the delivery of the first car.
DTC shall review the draft within two (2) months of delivery and provide comments
to the Contractor for incorporation into the final copies of the manuals.
Following the distribution of the final copies of the manuals, the Contractor shall be
responsible for issuing to DTC all necessary corrections and changes for each
manual throughout the life of the Contract and warranty period.
These revisions shall correct all inaccuracies, omissions, inconsistencies, and
manual workmanship determined during equipment usage, Contractor generated
design or production changes to the equipment and changes to approved
procedures and schedules.
Revisions shall begin not later than 90 days after distribution of the final copies of
the manual affected, and shall be made at least semi-annually. Revisions which
affect personal safety, or whose delay might be deleterious to equipment through
improper operation or maintenance, shall be incorporated immediately.
In the case of equipment changes, manual revisions shall be supplied before or
coincidental with the delivery of the altered parts or components.


Issue Date: 3/28/05                     18-2
IFB 4-002 TECHNICAL SPECIFICATION                                18 - DOCUMENTATION


18.2.3 Printed Maintenance and Parts Manuals

The Contractor shall furnish hard-copy printed manuals to DTC in two versions: 1)
Master Reproducible copy, and 2) Bound copies for general office and shop use.
The Contractor shall furnish DTC with one (1) final reproducible master of all
manuals, except as otherwise noted herein, including reproducible artwork and
assembly sheets. These shall be complete in all respects for photographic
reproduction. The master hard copy manual shall be bound in loose-leaf binders.
The printed and bound publications for general use shall be designed for continuous,
long-term service in a shop environment.
Maintenance Manuals, Parts Manuals and Car History Books shall be 8-1/2” by 11"
pages. Foldouts may be 11” high by 17” long folded to fit the binders. A good quality
oil resistant bond paper shall be used, printed on both sides except for foldouts and
special cases. The image area shall be 7” by 10”. Pages shall be 3-hole punched,
4-1/4” center-to-center spacing with 5/16” holes and plastic reinforced edge.
All covers shall be approximately 1/16 inches thick, resistant to oil, moisture, and
wear, to a high degree commensurate with their intended uses in a shop
environment. Diagrams and illustrations shall be line drawings and shall not be
loose or in pockets.
Maintenance Manuals, Parts Manuals and Car History Books shall be assembled
into locking, ‘D’ ring binders with heavy plasticized covers suitable for shop use. The
Spine of each binder shall identify the appropriate manual by its category and
contents. All manuals shall be indexed.

18.2.4 Electronic Format

The Contractor shall supply DTC with electronic copies of each manual. The
electronic manuals shall be provided in two versions: 1) Master version that shall
allow for subsequent revisions, and 2) Read only version for general DTC personnel
use.
All materials in electronic format shall easily accessible on an IBM™ compatible,
Windows™ based computer system, and shall be readily printable on printers in
common use. Specialized software shall not be necessary to print manual copies.
All electronic copies shall be provided on CD-ROM media. Each CD-ROM disc shall
be identified with permanent labels describing the contents of the CD.
The Master Version shall be supplied on CD-ROM in Microsoft Word™ (latest
version) or other DTC approved software system that shall allow for DTC to revise
and reprint the manuals. Two (2) complete CD-ROM sets of each Master Version of
the electronic manuals shall be supplied.
The general use manuals shall be supplied on CD-ROM in Adobe Acrobat™ (latest
version) or other DTC approved read-only software. Ten (10) complete CD-ROM
sets of each read-only electronic manual shall be provided.



Issue Date: 3/28/05                    18-3
IFB 4-002 TECHNICAL SPECIFICATION                                  18 - DOCUMENTATION


18.2.5 Technical Drawings

The Contractor shall furnish hard copy and electronic format copies of the latest
revision of all Contractor and Vendor/Sub-Contractor Engineering Drawings
produced for the “As-Overhauled” vehicle configuration. This shall include drawings
for all updated, revised or new systems and sub-systems on the vehicle.
Two (2) full size and one (1) 11”x17” size paper print set of each drawing shall be
provided. The Contractor shall also furnish the same drawings in an Adobe
Acrobat™ PDF and AutoCAD electronic format on CD-ROM. The Contractor shall
determine what version of AutoCAD the DTC presently uses and if it is not
compatible with that used by the Contractor, the Contractor shall provide at no cost
to DTC the software used, and, if necessary, hardware to provide compatibility and
full functionality of the Contractor’s files.
Two(2) CD-ROM drawing sets shall be provided in AutoCAD format and ten (10)
CD-ROM drawing sets shall be provided in Adobe Acrobat™ PDF format.

18.2.6 Conversion of Existing Microfiche Drawings to CD-ROM

DTC has a set of original UTDC supplied DPM drawings on micro film. The
Contractor shall review the drawings and provide a complete set of all pertinent
drawings, both existing and “As-Overhauled”, in electronic format. The Contractor
shall submit for DTC review and approval a list of all drawings to be deleted.
As an option to of this Contract, the Contractor shall provide services to copy and
convert all existing original UTDC and Vendor/Sub-Contractor drawings for the DPM
vehicles from a microfiche format to a CD-ROM format. It is estimated that there are
(quantity TBD) drawings on microfiche that shall require conversion to CD-ROM
format.
The CD-ROM drawing copies shall be in Adobe Acrobat™ PDF format, with
resolution adjusted such that when the converted drawing is viewed on a computer
screen and/or printed at full size (original printed size) all portions of the drawing are
clear with no appreciable detail loss from the original microfiche copy. Color
drawings (such as schematics), if present shall be copied in color.
The drawings shall be organized and indexed by the Contractor on the CD-ROM
according to the convention adopted for the organization of the maintenance and
parts manuals and other drawings to allow for easy identification and location of any
subject or drawing.
If this option is exercised, Contractor shall incorporate the Contractor’s “As-
Overhauled” drawing sets into the original UTDC-DPM drawing sets to provide for a
single, unified drawing set that is reflective of the entire vehicle upon completion of
the overhaul process.




Issue Date: 3/28/05                      18-4
IFB 4-002 TECHNICAL SPECIFICATION                               18 - DOCUMENTATION


18.2.7 Operating Instruction Books

The Contractor shall provide Operating Instruction Books, which shall contain all
information necessary for the successful automatic or hostler operation of the cars,
including:
   •   General car familiarization material.
   •   Location, function and operation of all controls, gauges, indicators and
       switches.
   •   Emergency procedures.
   •   Trouble symptoms and diagnosis methods.
   •   Discussion of the trucks, couplers, lights, door system, environmental control,
       ATC system, Vehicle Communication System and other features of the car
       which the DTC staff should have some basic knowledge.
The Contractor shall submit three (3) draft copies of the Operating Instruction Book
to DTC for review and approval four (4) weeks prior to the delivery of the first car.
The Contractor shall provide two (2) reproducible masters and twenty (20) final
copies of the Operating Instruction Book with or prior to delivery of the last car,
unless otherwise instructed by DTC.
The size of the books shall be 9.25" x 4.25" wire bound using a DTC approved
system on the long edge, with durable colored glossy cover stock.

18.2.8 Maintenance Manuals

The Contractor shall provide complete, new Maintenance Manuals. The Contractor
may utilize information found in the existing Detroit Downtown People Mover UTDC
Maintenance Manuals, but shall provide a new, more "modern" set of
comprehensive Maintenance Manuals that reflect the “As Overhauled” vehicle
configuration. The Maintenance Manuals shall include both running maintenance
and overhaul maintenance information.
The new Maintenance Manuals shall provide complete definition of all vehicle
subsystems, including the modified physical arrangements, new systems, and
individual system modifications incorporated through the overhaul.                The
maintenance concept shall address components to the lowest level identified in the
parts Manual. The manuals shall contain a detailed analysis of each component so
that maintenance personnel can effectively service, inspect, maintain, adjust,
troubleshoot, repair, replace and overhaul the equipment. Where interfaces occur, a
cross reference shall be made to the appropriate location. Diagrams and exploded
views shall be utilized to identify the location of parts within a sub-assembly and of
that sub-assembly within each larger assembly.




Issue Date: 3/28/05                     18-5
IFB 4-002 TECHNICAL SPECIFICATION                               18 - DOCUMENTATION


Each section of the Maintenance Manuals shall include, as a minimum, system
description and specifications, theory of operation, operating procedures,
troubleshooting (with logic/flow charts, as required), recommended preventive
maintenance, corrective maintenance, and complete disassembly and assembly
information.
Car specific information for arrangements and components shall be defined clearly
with respect to equipment supplier manuals which are to be provided for inclusion in
the manual.
Three (3) complete draft sets of Maintenance Manuals, including all cuts and
diagrams, shall be submitted for review by DTC no less than four (4) weeks prior to
delivery of the first car.
The Contractor shall provide one (1) reproducible master and fifteen (15) final copies
of the Maintenance Manuals with or prior to delivery of the last car.
The Contractor shall subsequently provide replacement pages as necessary to
reflect changes incorporated during the warranty period.
Drafts of Manuals may be used for Training. It is intended that the Maintenance
Manuals, Parts Manuals and Operator's Manuals shall be revised after completion of
Training.

18.2.9 Parts Manuals

The Parts Manuals shall enumerate and describe every component with its related
parts, including the accepted generic modified noun name description, the original
supplier's part number and name, the Contractor's part number, if used, all
commercial equivalents, and provision for entry of DTC's stock number. The
Contractor shall incorporate original Detroit Downtown People Mover UTDC OEM
Manual parts information which still pertains to the overhauled car configuration. The
Parts Manuals shall be new documents.
DTC shall be afforded the opportunity to identify parts with DTC's stock number in
the draft version of the Parts Manual for inclusion in the final Parts Manual by the
Contractor.
Cutaway and exploded drawings shall be used to permit identification of each and all
parts.
Parts common to multiple components (e.g., fasteners) shall bear the same part
number, with reference to all components in which they are found.
Each part or other component shall be identified as being part of the next larger
assembly.
Information relative to material, coating, if any, all dimensions, type, and ANSI
classification shall be included for fastener hardware (nuts, bolts, etc.).
The Parts Manuals shall include approved indexes that cross reference Contractor
part numbers, supplier part numbers, DTC stock numbers, and page numbers, with
figure and item numbers included.

Issue Date: 3/28/05                    18-6
IFB 4-002 TECHNICAL SPECIFICATION                                18 - DOCUMENTATION


The Contractor shall submit three (3) draft copies of the Parts Manuals to the DTC
for review no later than four (4) weeks prior to delivery of the first car.
The Contractor shall provide one (1) master and ten (10) final copies of the Parts
Manuals with or prior to delivery of the last car.
During the warranty period, the Contractor shall provide replacement pages as
necessary so these manuals reflect any changes from the original parts listing to the
end of the warranty period.

18.2.10    Car History Books

The Contractor shall furnish to the DTC Car History Books documenting and
containing the following information:
   •   Car Number
   •   Written report of each test performed on the car or its apparatus.
   •   Serial numbers of all wheels, axles, trucks, LIM, HVAC components, and any
       other apparatus with serial numbers on the car
   •   Weight of car, including weight by truck
   •   Wheel and axle mounting records
   •   Final Inspection Sheets, including:
           - Receiving Inspection at time of Shipment to cars Contractor.
           - Copy of Open Items on Shipping Release
   •   Tab for Conditional and Final Acceptance Documents
   •   Tab for Acceptance and Revenue Testing at DTC
   •   Torquing of disk brake hubs to axle
   •   Repairs to carbody frame, yokes, couplers and truck frames
The Contractor shall confer with DTC as to the format of these records.
It shall be the responsibility of the Contractor to employ an acceptable system of
configuration control in keeping individual Car History Books current.
The Car History Book for each car shall be delivered to DTC at the same time as the
delivery of the associated car to DTC.

18.3   TRAINING

Scope of training for the overhauled cars shall include all systems newly introduced
to the DPM vehicles and any system that DTC deems requiring a refresher.




Issue Date: 3/28/05                    18-7
IFB 4-002 TECHNICAL SPECIFICATION                                   18 - DOCUMENTATION


As a minimum, training shall be provided for the brakes system, doors, LIM
Propulsion System, and VOBC. The courses of training shall be prepared and
presented to personnel that shall be responsible for operation and maintenance
(O&M) of the Detroit People Mover System. It is understood that a portion of training
shall be provided by the Contractor's Personnel and a portion of Training shall be
provided by Vendor Personnel.

18.3.1 Training Class Requirements

Class size shall be assumed to be five (5).
Each course shall be offered twice, once on the day shift (8:00 am to 4:00 pm shift)
and once on the evening shift (4:00 pm to 12:00 midnight). Training shall occur by
the delivery of the first car.
Estimated duration for courses shall be assumed as follows:
   •   Brakes                                            6 hours
   •   Doors                                             6 hours
   •   LIM Propulsion System & ATC                       TBD hours
   •   DPM System Operation and Troubleshooting          TBD hours

18.3.2 Training Materials and Presentations

A Training Plan shall be written by the Contractor and submitted before the delivery
of the first car.     Training shall stress corrective maintenance, preventive
maintenance and system operation and troubleshooting in equal proportion.
The Training Plan and all associated Student Guides, Instructor Guides, Notes, and
other Technical Documentation shall be submitted to the DTC for review and
approval. The Training Plan and all associated documentation shall become the
property of the DTC when training is completed.
New Operating Instruction Books, Maintenance Manuals and Parts Manuals shall be
the basis for the technical content of the courses. Lesson plans shall be
supplemented by the system drawings and manuals, which are the primary training
references. Additional reference materials required for the training sessions shall be
provided by the Contractor.
Lesson plans shall be prepared for all training presentations and shall be included in
the Instructor Guides developed for each course.
Each lesson plan shall include, but not be limited to:
   •   A list of lesson objectives.
   •   A list of training materials to be used during the lesson.
   •   An outline of the training presentation.
   •   The instructor's personal notes.


Issue Date: 3/28/05                       18-8
IFB 4-002 TECHNICAL SPECIFICATION                               18 - DOCUMENTATION


   •   Student worksheets, when applicable.
   •   Student examinations.
   •   Copies of all transparencies (or other media) used during the lesson.
Lesson objectives shall be geared to a technician with two years of technical school
and one year experience maintaining DTC People Mover equipment. Assume
reading and comprehension level to be sixth grade. The lesson objective shall, at a
minimum, indicate:
   •   Specific knowledge or capabilities to be acquired by the student as a result of
       training.
   •   Criteria which shall be used to determine if the student has achieved the
       stated objectives (examination and evaluation).
   •   Conditions under which the student shall be evaluated.
Training shall be accomplished through classroom lectures, laboratory
demonstrations or exercises, video training tapes (or DVDs) and self study.
Training shall include both classroom lectures and hands-on maintenance exercises
and demonstrations. Hands-on training shall be approximately 50% of the training
time. The Contractor shall make arrangements in advance with DTC for vehicles
and/or components to be made available for training purposes.
Student training materials shall include Student Guides and copies of the applicable
manuals and system drawings. One set of training materials shall be provided to
each student. Student Guides shall be prepared for each course and shall include
pertinent information extracted from the Instructor Guides. Information shall include
items such as lesson objectives, an outline of each presentation, and copies of all
transparencies used during the presentation.
One complete set of Training Material, including overheads, slides, videos, DVDs,
models shall be given to DTC at the completion of Training.

18.3.3 Evaluations and Certification

Levels of student competence shall be established through examinations that shall
determine if the student has acquired the basic knowledge, capabilities and
understanding of safe work practices specified by the lesson objectives. Evaluations
may include written or oral quizzes and/or demonstrations and may be conducted by
the Contractor's Instructor. The results of all evaluations shall be made known to the
student and shall be maintained by the Staff Instructor. Examinations, Evaluations
and Certification shall become part of an employee's permanent record.


                                   End of Section




Issue Date: 3/28/05                    18-9

				
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