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Overhaul of SD40-3 Locomotive
1
013121-001 • May 2020
Motive Power & Equipment Solutions, Inc.
Overhaul Specification for the
Supply of an Overhauled SD40-3 Mainline Locomotive
Scope #: 013121-001v2
Overhaul of SD40-3 Locomotive
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013121-001 • May 2020
REV
DATE
MODIFICATION
PREPARED
BY
REVIEWED SUBMITTED APPROVED
BY BY BY
0
1
10-10-2020
Initial Release
DWE
TD
DWE
TM
11-10-2020
Minor revision
TD
DL
TD
TM
2
Overhaul of SD40-3 Locomotive
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013121-001 • May 2020
TABLE OF CONTENTS
PAGE
1 GENERAL .....................................................................................................................................7
1.1 DESCRIPTION OF THE WORKS..................................................................................................... 7
1.2 POINT OF DELIVERY..................................................................................................................... 7
1.3 CONTEXT OF THE WORKS ........................................................................................................... 7
1.3.1 Operating environment.......................................................................................................... 7
1.4 DEFINITIONS................................................................................................................................ 7
1.5 ABBREVIATIONS/NOMENCLATURE............................................................................................. 8
2 SCOPE........................................................................................................................................10
2.1 DESIGN ......................................................................................................................................10
2.1.1 Supply .......................................................................................................................................10
3 DOCUMENTATION .....................................................................................................................10
3.1 REFERENCE DRAWINGS ............................................................................................................11
3.2 STANDARDS AND REGULATIONS ..............................................................................................11
3.3 DOCUMENTATION TO BE SUPPLIED BY THE CONTRACTOR......................................................11
4 LOCOMOTIVE TECHNICAL SPECIFICATIONS .................................................................................11
5 MINIMUM OVERHAUL REQUIREMENTS......................................................................................
5.1 FRAME....................................................................................................................................... 12
5.2 FUEL TANK AND FUEL SYSTEM.................................................................................................. 12
5.3 DRAFT GEAR AND COUPLER...................................................................................................... 12
5.4 CAB SHORTHOOD (LOW NOSE)................................................................................................. 13
5.5 DRIVING CAB............................................................................................................................. 13
5.6 CONSOLE CONTROLLER (NON-DASH 2 LOCOMOTIVES ONLY) ................................................. 14
5.7 SPEED INDICATOR ..................................................................................................................... 14
5.8 EVENT RECORDER ..................................................................................................................... 14
5.9 CARBODY LONGHOOD .............................................................................................................. 14
5.10 LIGHTING SYSTEM..................................................................................................................... 15
5.11 HIGH VOLTAGE CABINET........................................................................................................... 16
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5.12 MAIN GENERATOR – AR10/D14................................................................................................ 16
5.13 AUXILIARY GENERATOR ............................................................................................................ 16
5.14 ENGINE...................................................................................................................................... 16
5.15 EXHAUST SYSTEM ..................................................................................................................... 17
5.16 FUEL SYSTEM............................................................................................................................. 17
5.17 RADIATORS................................................................................................................................ 17
5.18 EQUIPMENT RACK..................................................................................................................... 18
5.19 LUBE OIL COOLER...................................................................................................................... 18
5.20 COOLING FANS.......................................................................................................................... 18
5.21 ELECTRICAL CABINET................................................................................................................. 18
5.22 WBO AIR COMPRESSOR ............................................................................................................ 18
5.23 AIR BRAKE SCHEDULE – 26L ...................................................................................................... 19
5.24 BOGIES ...................................................................................................................................... 20
5.25 SANDING ................................................................................................................................... 20
5.26 HAND BRAKE ............................................................................................................................. 20
5.27 WIRE, CABLE, CONDUIT ............................................................................................................ 21
5.28 TRACTION MOTORS .................................................................................................................. 21
5.29 BATTERIES ................................................................................................................................. 21
6 MATERIALS AND WORKMANSHIP...............................................................................................22
6.1 OVERALL REQUIREMENTS......................................................................................................... 22
6.2 CLEANING.................................................................................................................................. 22
6.3 CORROSION PROTECTION......................................................................................................... 23
6.4 FASTENERS ................................................................................................................................ 23
6.5 METAL PRODUCTS .................................................................................................................... 24
6.5.1 STEEL CASTINGS…………........................................................................................................ 24
6.5.2 STAINLESS STEEL.................................................................................................................. 24
6.5.3 STRUCTURAL STEEL ................................................................................................................. 24
6.6 ELASTOMERS............................................................................................................................. 24
6.7 GLASS ........................................................................................................................................ 24
6.8 PIPING AND TUBING ................................................................................................................. 24
6.9 WIRE AND CABLE ...................................................................................................................... 25
6.9.1 CONDUCTORS........................................................................................................... 25
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6.9.2 INSULATION.............................................................................................................. 26
6.10 WIRING...................................................................................................................................... 26
6.10.1 GENERAL................................................................................................................... 26
6.10.2 GROUNDING............................................................................................................. 27
6.10.3 TERMINATIONS......................................................................................................... 27
6.10.4 UNDERFRAME........................................................................................................... 27
6.10.5 CONDUITS................................................................................................................. 28
6.10.6 CABINETS AND CONDUIT BOXES .............................................................................. 28
6.11 WELDING................................................................................................................................... 28
6.11.1 WELDING RESPONSIBILITY........................................................................................ 28
6.11.2 WELD PREPARATION ................................................................................................ 28
6.12 PAINTING .................................................................................................................................. 29
7 TESTING.....................................................................................................................................29
7.1 FINAL TEST ................................................................................................................................ 29
7.2 TEST RUN................................................................................................................................... 30
7.3 PRE-SHIPMENT INSPECTION ..................................................................................................... 30
7.4 SITE TESTS ................................................................................................................................. 30
8 QUALITY ....................................................................................................................................31
8.1 GENERAL ................................................................................................................................... 31
8.2 QUALITY ASSURANCE................................................................................................................ 31
8.3 INSPECTION, HOLD AND WITNESS POINT REQUIREMENTS...................................................... 31
9 SPARES ......................................................................................................................................32
10 SPECIFIC PACKING, HANDLING TRANSPORT AND STORAGE REQUIREMENTS................................32
11 DRAWING AND DATA REQUIREMENTS .......................................................................................33
11.1 GENERAL ................................................................................................................................... 33
11.2 SUBMISSION AND REVIEW........................................................................................................ 33
11.3 DRAWINGS AND DATA.............................................................................................................. 33
11.4 SCHEDULE OF DRAWING AND DATA REQUIREMENTS ............................................................. 33
12 WARRANTY ...............................................................................................................................34
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LIST OF TABLES
Table 1 - Description of Equipment to be Delivered.....................................................................................7
Table 2 - Reference Drawings .......................................................................................................................11
Table 3 - Locomotive Technical Specifications ...........................................................................................11
Table 4 - Minimum hold and witness point requirements .........................................................................3
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1 GENERAL
1.1 DESCRIPTION OF THE WORKS
The scope of supply comprises of the provision of all labor, materials, equipment and services
necessary to overhauled and offer optional assistance with commissioning relating to the following
equipment:
Table 1 - Description of Equipment to be Delivered
150 metric ton Gross Rail Load, standard gauge OVERHAULED EMD SD40-2 to SD40-3
LOCOMOTIVES to SD40-3 LOCOMOTIVE with a microprocessor-based control system and ECP Braking
In this document, the SD40-3 is defined as an SD40, SD40-1 or SD40-2 locomotive equipped with a
modernized TMV microprocessor-based traction control system allowing:
1- To improve adhesion and useable tractive effort at low speed.
2- Isolating (cutting out) traction motors individually.
1.2 POINT OF DELIVERY
The Works shall be delivered to Greenville, SC according.
1.3 CONTEXT OF THE WORKS
The locomotives will be overhauled to work in a single and or multiple units to train configuration.
1.3.1 OPERATING ENVIRONMENT
The locomotive shall be adapted to the climatic conditions and operating environment prevailing on the
railway as designed by the OEM (EMD).
1.4 DEFINITIONS
Standard AAR definitions will apply.
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1.5 ABBREVIATIONS/NOMENCLATURE AAR Association of American Railroads
AAR Standards
ANSI
ASTM
AWG
ASM
CFR
The AAR Manuals of Standards and Recommended Practices (MSRP).
American National Standards Institute
American Society for Testing and Materials
American Wire Gauge
American Society of Metals
Code of Federal Regulations
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Contract
Contractor
AWS
EMD
FRA
GP
IOM
IP
ISO
ITP
kPa
Locomotive
MDR
MSDS
MTPA
MU
NEC
NEMA
OEM
PCS
psi
SAE
SD
SI
SSPC
QA
The agreement between the Company and the Contractor
The person or company appointed by the Company to execute the work under
the contract
American Welding Station
Electro Motive Division of General Motors / ElectroMotive Diesel
The United States of America Federal Railroad Administration
General Purpose
Installation Operations and Maintenance Manual
Inspection Procedures
International Standards Organization
Inspection Testing Procedures
Kilopascals
The Work to be supplied by the Contractor to the Company
Manufacturers Data Report
Materials Safety Data Sheet
Million tons per annum
Multiple Unit
National Electrical Code
National Electrical Manufacturers Association
Original Equipment Manufacturer
Protective Coating System
Pounds per Square Inch
Society of Automotive Engineers
Special Duty
System International
Society for Protective Coatings
Quality Assurance
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013121-001 • May 2020
2 SCOPE
The Work shall be supplied complete and operational except as specifically excluded and shall include all
necessary auxiliary equipment, accessories and the incorporation of all miscellaneous material, minor
parts and other such items, whether or not the items are specified, where it is clearly the intention that
they should be supplied or where they are obviously required and necessary to complete the
equipment.
The scope of supply shall include, but is not limited to the following:
2.1 DESIGN
� Cab modifications to allow for a dual operator control stand cab configuration.
2.1.1 SUPPLY
The scope shall include:
� The supply of 150 metric ton Gross Rail Load, standard gauge OVERHAULED EMD SD-40/SD40-2
LOCOMOTIVES to SDL40-3 LOCOMOTIVES, hereafter named Locomotive(s), for service in high-
mileage unit trains.
� Provision of instruction and maintenance manuals.
� Provision of drawings, spare part lists, operation manual for all equipment applied on the locomotive
as part of the works and which differs from the equipment originally applied by the locomotive
as available from the OEM.
3 DOCUMENTATION
All material, equipment and workmanship to be furnished by the Contractor shall conform to the
requirements of the following documents and they shall form part of the Contract. The Contractor
should note that if there is any doubt, the hierarchy of the documents is as indicated below:
� This Scope of Works Document;
� All relevant Drawings and subsidiary Scopes of Works;
� Rules and regulations applicable in the Jurisdiction where the Works are used;
� The latest editions of relevant project specifications;
� International design standards; and
� All other relevant publications.
Where the Contractor’s standards are in conflict with the requirements of the contract documentation,
the Contractor shall list those technical exceptions in applicable documentation.
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3.1 REFERENCE DRAWINGS
Available OEM Drawings of existing locomotives may be used as a guide t he Contractor.
Table 2 - Reference Drawings
Document Number
Title
AAR MSRP Standard S-5510
AAR MSRP Plate L – Locomotive Diagram for Interchange Service
3.2 STANDARDS AND REGULATIONS
The Contractor shall ensure that all work carried out under this Contract complies with the
latest versions of all relevant AAR standards and FRA regulations.
3.3 DOCUMENTATION TO BE SUPPLIED BY THE CONTRACTOR
As part of its Proposal, the Contractor shall provide, as a minimum, the following information:
� Contractor to provide a digital copy of the QA Manual for each unit.
4 LOCOMOTIVE TECHNICAL SPECIFICATIONS
Table 3 - Locomotive Technical Specifications
Model to be Rebuilt
SD40/SD40-2
Rebuilt Model Designation
SD40-3 Microprocessor Controlled
Net Tractive Horsepower
2237 kW (3000 hp)
Total Weight
150 metric tons (330,693 lbs) See note 4 on Spec. Sheet
Max Load per Axle
25. metric tons (55,116 lbs) See note 4 on Spec. Sheet
Max Speed
105 km/h (65 mph)
Engine
16-645E3B
Main Generator
AR10-D14
Auxiliary Generator
18KW (AC)
Traction Motor
D78
Air Brake Remove existing Brake system and install fast brake with ECP
Manufactured by WABTEC.
Sand Capacity
1586 L (56 Cu. Ft.)
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013121-001 • May 2020
5.1 FRAME
1. Inspect the complete frame for cracks and wear, with a special attention to the following areas:
a) Center castings
b) Air ducts
c) Fuel tank supports
d) Piping around clamps and where pipes pass through frame
e) Draft gear pockets
Repair as necessary
2. Check frame alignment to ensure it is within OEM tolerances. Alignment to be transit checked if
proper profile is in doubt.
3. Repair all major structural defects.
4. Inspect front and rear pilot plates. Repair as necessary. Remove snow plough if equipped.
5. Inspect end plates and supports. Repair as necessary.
6. Qualify frame wear plates, repair as required.
7. Qualify floor plate over sump in area behind the high voltage cabinet. Repair as required.
8. Inspect main generator wall partition. Repair as necessary.
9. Modify air brake and battery box doors to lift-off configuration.
10. Retain handrail and stanchion design in-kind, repair as necessary.
11. Retain grab iron arrangements in kind. Repair as necessary.
12. Install all new MU hoses and brake cylinder hoses.
5.2 FUEL TANK AND FUEL SYSTEM
13. Fuel tank shall be cleaned out, inspected for corrosion and leak tested (cleaned with steam).
14. The fuel tanks shall have a minimum capacity of 6000 L (1585 U.S. Gal.) with a 380 L (100 U.S.
Gal.) retention tank.
15. Apply electronic fuel gauges at Fuel tank.
16. Fuel piping shall be repaired as necessary.
5.3 DRAFT GEAR AND COUPLER
19. Visually inspect draft gear pocket for cracks, wear and damage. New couplers and draft gears.
20. Couplers to be AAR “F-type”, if couplers are “E-type”, they are to be replaced with AAR “F-type”
couplers.
21. Coupler height to meet AAR requirements: 876.3 mm (34 ½”) above top of rail.
22. Draft gears and couplers shall meet FRA and AAR regulations.
23. New model NC390 draft gears shall be applied.
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5.4 CAB SHORTHOOD (LOW NOSE)
24. Short hood Toilet Compartment:
a) Retention tanks and toilets shall be removed if equipped.
5.5 DRIVING CAB
26. Remove conductor’s desk (If Equipped)
27. Install two (2), SD40-2 style, AAR control stands in the locomotive.
28. Remove insulation material in cab roof and apply new insulating and install new perforated metal.
29. Install recondition air conditioning unit in ceiling of cab.
30. Install new style cab ceiling lights in cab ceiling if not equipped already.
31. Repair or replace existing cab floor as necessary. Material used shall be plywood with a thickness
of 19 to 32 mm (¾” to 1-1/4”).
32. Apply new floor covering.
33. Qualify existing cab doors, ensuring they are not rotten or distorted. Replace doors as required.
34. Inspect window glazing and replace as necessary. Ensure that FRA compliant glazing is applied.
Inspect seals of all fix windows and ensure they are air and water leak tight. Replace seals if they
are cracked or damaged.
35. Inspect side sliding windows. Ensure window frames are properly bolted to the carbody and
properly sealed to prevent water infiltration. Ensure that windows are sliding easily and that they
are equipped with locks. Ensure that glazing is not damaged and are AAR compliant. Repair or
replace any damaged or missing components.
36. Apply three new seats.
a) Seats in the driving positions are to be high backrest, equipped with fabric cushion covering
and with adjustable armrests. They shall be height and fore and aft adjustable.
b) The third seat shall be a foldable jump seat mounted on the electrical cabinet.
37. If not already equipped, apply clean cab.
a) Pull handle and rubber hinge guard for cab doors.
b) Head bump pads.
c) Push button horn button.
d) Padded sun visor.
e) Plastic wiper motor covers.
f) Rubber grip for wiper handle.
g) Three (3) coat hooks.
h) Provide outside access number boards and seal existing interior access doors.
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013121-001 • May 2020
38. Wipers and wiper motors shall be electric powered.
39. Install metal folding cab awnings, qualify existing if locomotive is already equipped.
40. Repair horizontal handholds as necessary on front and top of short nose.
5.6 CONSOLE CONTROLLER (NON-DASH 2 LOCOMOTIVES ONLY)
46. If not already equipped, install a AAR control stand.
47. Wiring to be pliable and meet standard OEM standards for cables during overall or replaced with new.
48. Install the following switches:
a) Sand switch.
b) Lead truck sand.
c) Two (2) headlight switches, one for front and one for rear.
d) Ground relay reset.
e) Control and Engine run switches.
f) Nameplate for all switches (eng. run, gen. field, control, fuel pump, etc.)
g) Ditch light switch.
49. Install gauge lights if not equipped.
50. Install bell operating valve.
51. Install horn operating mushroom button.
52. Salem 4-1/2 inch air gauges to be installed if not already equipped. Equipped with the third
#796-151 air flow gauge.
53. Qualify Vigilance Control device (Dead Man’s Device). Repair if required.
5.7 SPEED INDICATOR
54. Install HMI and provide display for KPH.
5.8 EVENT RECORDER
56. Install a qualified FRA-compliant Event Recorder.
57. The memory of the event recorder shall meet FRA and AAR minimum requirements.
58. The event recorder shall record critical systems as outlined by AAR and FRA.
5.9 CARBODY LONGHOOD
59. Remove hood – strip out all components.
60. Perform corrosion repairs.
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013121-001 • May 2020
61. Qualify or repair all door hinges.
62. Qualify or repair all door latches.
63. Inspect and clean out radiator compartments, renew rusted out sections.
64. Repair dynamic brake hatch as necessary.
65. Inspect existing cooling fan receptacles and repair as necessary if signs or arcing are present.
Install cooling fans (reference cooling Fan Section).
66. Complete long hood shall be sandblasted, primed and painted (see Paint section).
67. Qualify low voltage wiring and contactors and replace as required.
68. Repair grab irons as necessary and insure application in conformance with FRA requirements.
Curved grab iron at rear cooling fan in-kind.
69. Dynamic Brakes.
a) Qualify cables as required.
b) Clean, inspect and test grids, replace as necessary.
c) Qualify and rebrush grid blower motors. Repair as necessary.
d) Extended range braking shall be supplied.
70. New number boards shall be installed at both ends of the locomotive. Road numbers to be
supplied by the Company.
71. New bag type engine air filter elements shall be installed in qualified and cleaned filter boxes.
72. Inertial shall be removed, cleaned and repaired as required and reinstalled.
73. Car body braces shall be applied if not equipped.
74. Qualify/replace shutter assemblies and screen as required.
5.10 LIGHTING SYSTEM
75. Install qualified headlight assemblies at front and rear end of locomotive.
76. The front headlight mounting position shall be between number lights on the front cab wall.
77. Install qualified headlight resistor – headlight voltage should be; dim 14V, medium 22V, bright 30V
(variance +1-0 V).
78. Install ditch lights on the front end of the locomotive.
79. If present, class lights shall be removed, compartment shall be blanked-off and welded smooth.
80. Step lights shall be installed at front and rear steps.
81. Ditch lights shall be installed on the front end (short hood end) of the locomotive.
82. Repair walkway lights if equipped as necessary.
83. Repair existing step lights or install new if unit is not so equipped.
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013121-001 • May 2020
5.11 HIGH VOLTAGE CABINET
84. Qualify electrical high and low voltage cabling and prepare make necessary modification:
a) Install new TMV microprocessor-based control system.
85. Install baggy type filters for cabinet pressurization.
86. Qualify electrical cabinet rewire as necessary.
87. Electric cabinet shall be insulated and sealed.
88. All terminal boards, lugs, wiring and cabling shall comply with OEM specs.
89. Interior of electric cabinet shall be cleaned as necessary.
5.12 MAIN GENERATOR – AR10/D14
90. An AR10/D14 Main Generator overhauled according to EMD MI 3317-2 D.
5.13 AUXILIARY GENERATOR
91. An 18KW, A.C. auxiliary generator overhauled according to EMD MI specifications.
5.14 ENGINE
92. Engine shall be 16-645E3B.
93. Engine shall be removed from locomotive.
94. Old oil shall be drained and engine flushed.
95. Crankcase and oil pan shall be disassembled and cleaned thoroughly.
96. Crankcase shall be qualified or renewed as necessary.
97. A-frame and line bore shall be inspected, measured and repaired as necessary.
98. Crankshaft and camshafts shall be inspected for cracks, wear and other damages and replaced as
required
99. Install new power assemblies.
100. Engine gear train shall be qualified. Worn or defective component shall be repaired or replaced as
required.
101. Apply rebuilt water pumps
102. Apply a rebuilt oil pump
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013121-001 • May 2020
103. Install new main bearings and connecting rod bearings.
104. Renew all gaskets and seals
105. Install new power assemblies.
106. Install new spin-on fuel filters.
107. Qualify top deck components. Replace as required.
108. Rebuilt injectors and valve bridges shall be installed.
109. Set injector racks and timing.
110. Check governor and lay shaft alignment.
111. Set exhaust valves.
112. Install new turbocharger.
113. Install rebuilt or new starter motors.
114. Apply new Low water/crankcase pressure detector and engine protection device.
115. Engine shall be free of oil, exhaust and water leaks.
116. Water system shall be tested with 15 lbs. of pressure and all leaks repaired.
5.15 EXHAUST SYSTEM
120. Qualify exhaust manifolds and expansion joints. Repair or replace as necessary. Apply new gaskets
5.16 FUEL SYSTEM
121. A new AC fuel pump motor shall be applied.
122. Inspect electric emergency fuel shut off system. Replace switches as necessary.
123. Clean the primary fuel filter housing.
5.17 RADIATORS
124. Install mechanically bonded radiators.
(If not equipped).
125. Water test assembled radiator Section at 30 psi.
126. Water piping shall be repaired as necessary.
127. All asbestos wrapping shall be removed from the complete locomotive.
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013121-001 • May 2020
5.18 EQUIPMENT RACK
128. Qualify and clean the 7 element (Michiana) lube oil filter tank and apply new filter elements.
Remove and clean relief valves and check spring tension.
129. Qualify water tank for pressurized system.
130. Repair/replace conduit as necessary and renew all wiring as necessary.
131. Renew small copper tubing and large piping only as required.
132. Install new load regulator part # 9317181.
133. Clean fuel oil suction strainer.
134. Qualify fuel filtration system in-kind and renew filter media.
135. Provide quick disconnect for lube oil filter pressure tap.
136. Apply governor plug boot as required.
5.19 LUBE OIL COOLER
137. Dismantle assembly.
138. Degrease heads and all other parts.
139. Qualify mechanical bond core and reassemble with all new gaskets.
140. Hydrostatic test complete assembly at 207 kPa (30 psi).
5.20 COOLING FANS
141. Qualify cooling fan motor as per EMD MI specifications.
142. Inspect rotor, impellers and other fan components for damage. Replace as required.
143. Assemble and test.
5.21 ELECTRICAL CABINET
144. If not already equipped, upgrade AC cabinet to Dash-2 fused configuration.
145. Inspect seals and weather-strip. Replace as required.
146. Qualify cabinet and rewire as required.
5.22 WBO AIR COMPRESSOR
147. Install rebuilt WBO air compressor.
148. Compressor control valves shall be qualified and repaired or replaced as required. Compressor
shall be set to start at 130 psi and to stop at 140 psi.
149. shutter control valves shall be qualified and repaired or replaced as required.
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013121-001 • May 2020
5.23 BRAKE SYSTEM
150. The Locomotive shall be equipped with a new microprocessor controlled air brake system. The
air brake system shall be able to apply the brakes of wagons equipped with conventional
air brakes, and wagons equipped with electronically controlled pneumatic (ECP) brakes.
151. The Locomotive shall be equipped for Electronically Controlled Pneumatic (ECP), Cable-Based
brake system.
152. The design and performance of the ECP Cable-Based brake system shall be in accordance with AAR
Standard S-4200 latest revision.
153. The ECP brake system Head End Unit (HEU) shall be integrated to the locomotive driver’s work
station in accordance with AAR Standard S-4200 latest revision.
154. Cables, connectors and junction boxes shall be in accordance with AAR Standard S-4210 latest
revision.
155.
156.
157.
158.
159.
160.
161.
162.
Locomotive shall be equipped with a DC Power supply in accordance with AAR Standard S-4220
latest revision.
Install ball type 1-1/4-inch angle cock. Angle cock must not be vented. All train line air piping
should be retained as is.
Worn piping and fittings shall be replaced as necessary.
Install new train line hoses.
Qualify fireman’s emergency brake valve.
Remanufacture existing air filters housings. Install new filter elements.
Air filters shall be equipped with drain valves.
Air flow gauge shall be supplied (see console section).
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013121-001 • May 2020
5.24 BOGIES/TRUCKS
163. Inspect for worn or over-riding brake shows and adjust brake travel, repair as required.
164. Check for loose/missing brake head guide bars or safety hangers, repair as required.
165. Inspect for loose or leaking shock absorbers. Repair/replace as required.
166. Inspect bogie equalizer safety hanger repaired as required.
167. Inspect pedestal liners for cracks. Replace as required.
168. Inspect for broken or collapsed springs. Replace as required.
169. Qualify bull gear and replace with new as necessary.
170. Remanufactured axles with new wheels and TIMKEN 6 7/8” X 12 “ GG bearings shall be applied.
171. Gear cases shall be grease lubricated. ensure a sufficient amount of grease is applied. Only
qualified metal gear cases with new type seals shall be supplied.
172. Fill suspension bearing boxes with oil to the proper level.
173. Lubricate center casting, if equipped with external lubrication device.
174. All brake cylinders will be rebuilt and free of all leakage.
175. New bogie brake hoses applied.
5.25 SANDING
176. Existing sanding system shall be checked for proper operation. Damaged or failed components
shall be repaired or replaced as required.
177. Qualify Salem magnet valves for sanding and shutter control. Traps shall be replaced as necessary.
178. Sand boxes shall be inspected and repaired as required. Filler covers shall close properly.
179. Piping shall be replaced as necessary.
180. Replace worn or spliced sand hose.
181. Lead sanding switch shall be located on the control stand.
182. Manual sanding switch shall be non-latching type.
5.26 HAND BRAKE
183. Qualify and adjust existing hand brake and chain.
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013121-001 • May 2020
5.27 WIRE, CABLE, CONDUIT
See also Wire and Cable Section 6.9
184. All wires and cables shall be qualified. Non qualifying cables shall be replaced.
185. Fast-on terminals – except stud type for No. 8 wire size or larger.
186. Control wire size to be consistent with industry/OEM standard.
187. No splices are to be pulled into conduit. All connections are to be at terminal boards where
possible, otherwise only in junction boxes or fittings.
188. Whenever wires or harnesses are laid on or bent around edges of metal or other material, anti-
chafing protection shall be provided between the wires and the edges.
189. All wires and cables to be identified at each termination. Wire markers must be suitable for diesel
use; oil and solvent resistant.
190. AAR standard 27 wire trainline shall be provided. All trainline wires to be #12 AWG. Shroud type
MU pins are to be used. Connection for the MU’s shall be made at the main terminal board and
terminal board located at the load regulator.
191. All wire to meet AAR Spec. 501. All replacement wire size #8 and smaller to be Exane.
5.28 TRACTION MOTORS
192. Traction motors shall be overhauled as per EMD MI 3900-G.
193. All suspension bearings shall be replaced with necessary.
194. All wicks shall be replaced.
5.29 BATTERIES
195. Paint interior of battery boxes with corrosive resistant coating.
196. Install eight (8) new individual, recharged batteries.
197. No unitized batteries shall be supplied
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6 MATERIALS AND WORKMANSHIP
6.1 OVERALL REQUIREMENTS
198. All materials to be used in the rebuilding of these locomotives shall be selected such that they
shall safely achieve their function, for the service life of the locomotives.
199. Overhauling shall conform to acceptable railroad industry standards.
200. Products or composite materials containing asbestos shall not be utilized.
201. Paints and coatings containing lead shall not be utilized.
202. Only materials and coatings, which will not be detrimentally affected by the appropriate use of
commercial cleaning agents (mild organic acid base; mild alkaline, no free base), fuels, lubricants,
coolants, corrosion inhibitors, and atmospheric pollutants shall be utilized.
203. Threaded fastenings and other machine elements, not specified elsewhere, shall conform to ASM,
SAE, ANSI, and ISO requirements, as applicable.
204. If hinges and latches are replaced, they shall be metallic and shall be protected from corrosion,
either by inherent material properties, or by auxiliary protective coatings/plating suitable for the
design life of the locomotives.
205. Newly applied pressure vessels shall conform to the latest revision of Section VIII of the ASTM
Boiler and Pressure Vessel Code for Unfired Pressure Vessels and shall be “tell-tale” hole drilled to
avoid periodic pressure testing.
206. All filters shall be as recommended by the manufacturer of the system or equipment involved.
207. Air filters shall be of the replaceable media type, unless otherwise indicated.
208. Fuel and lubricating oil filters shall be of the “throw-away” or replaceable cartridge type.
209. Non OEM components, that cannot be easily removed by one or two people, or weighs more
than 22.7 kg. (50 lbs.) shall include provisions for material handling.
210. The Contractor shall provide a material safety book including the material safety data sheets
(MSDS), for each material used on the locomotive.
6.2 CLEANING
211. All joining surfaces shall be clear and free of dirt, grease, scale and other contaminants prior to
attachment or joining.
212. During Locomotive overhaul, adequate care shall be taken to prevent drill cuttings and other
from accumulating in areas, which become inaccessible after subsequent assembly.
213. Where drilling or other work has to be performed after installation of air brake equipment and
piping, or electrical equipment and wiring, adequate precautions shall be taken to contain all drill
cuttings and other metallic debris.
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214. Before delivery of Locomotive, a final clean up shall be made to ensure all construction debris is
removed. Of particular concern are all electrical junction boxes, lockers, panels, heaters, electrical
terminal blocks, oil, water, fuel, and air, tanks and piping.
6.3 CORROSION PROTECTION
215. All joints, connections, and contact between dissimilar metals shall be suitably protected against
galvanic actions, to remain effective for the service life of the Locomotives.
216. All joints and surfaces shall be designed to allow moisture to drain clear without water traps and
pockets to initiate corrosion, and designed in a manner to avoid accumulation of leaves and other
natural debris.
6.4 FASTENERS
217. No protruding screws, mounting bolts or similar items shall be used on the interior and exterior of
the car body, except where components or appointments can be installed in no other manner and
still be removable for maintenance/repair.
218. Any exposed fasteners in the cab interior shall be stainless steel, Phillips drive, flat, pan or oval
head as appropriate.
219. Fasteners shall be coated with protective coatings as appropriate for the application.
220. Self-tapping screws shall not be used for any attachments requiring dismantling and re-fastening
during maintenance.
221. Drill jigs or other special tooling shall be utilized to ensure interchangeability of fabricated parts
and/or components.
222. Frequently accessed (for maintenance) panels may use quarter-turn square key latches.
223. Structural load-carrying bolts shall be SAE grade 5 minimum.
224. Bolts and nuts mounted on trucks and in other critical areas subject to high level of vibrations shall
be mechanically locked, secured by other means and or as applied by OEM.
225. At least 1½ screw thread shall be visible beyond all nuts.
226. Harden steel flat washers shall be used under the heads of all bolts and nuts.
227. All special fasteners or devices, such as Huck bolts, shall be applied per the manufacturer's
instructions.
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6.5 METAL PRODUCTS
6.5.1 STEEL CASTINGS
228. Steel castings shall be manufactured in accordance with AAR Specification M-201 or equivalent
ASTM Standards.
229. Weld repair of castings shall be permitted if performed by qualified welders in accordance with
the Contractor’s engineering and material standards.
6.5.2 STAINLESS STEEL
230. All grades of structural stainless steel shall be selected based on grade and specification consistent
with the application.
231. Non-structural stainless steel shall be AISI Types 201, 202, 302, 304 316, or 430 as applicable. The
chemical compositions shall conform to the requirements of SAE J405d.
6.5.3 STRUCTURAL STEEL
232. Carbon Steel shall conform, as a minimum, to the requirements of ASTM A36 or the Canadian
equivalent.
233. High Strength Low Alloy (HSLA) steel may be used in lieu of carbon steel.
234. HSLA steel for structural shapes, plates, and bars shall conform to the requirements of ASTM
A588, A572 grade 70, A710 grade A class 3 or the Canadian equivalents.
6.6 ELASTOMERS
235. Elastomers used in and around the cab shall conform to the requirements of ASTM C542, and shall
conform to the requirements of 49 CFR Ch. II § 238.103.
236. For all components consisting of elastomers bonded to metal, the strength of the elastomer-to-
metal bond shall exceed the tensile strength of the elastomer, when tested in accordance with
method A of ASTM D429.
237. Elastomers used in truck assemblies shall be suitable for the environment in which the truck
operates and be resistant to abrasion, oil, grease and acid.
6.7 GLASS
238. All glazing shall conform to the requirements of 49 CFR Ch.II § 223 and ANSI Z26.1.
6.8 PIPING AND TUBING
239. Compressed air piping shall be located and arranged so that it does not interfere with
maintenance and servicing of components and equipment.
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240. All piping, valves and fittings shall be service proven or conform to the ASME Code for Pressure
Piping B31.1.
241. Fittings shall be rated to the AAR 136 kg (300 lb.) standard.
242. Welded fittings and welded pipe joints shall be used wherever possible.
243. All piping shall be installed free of traps and pitched to provide drainage to prevent damage to
components.
244. All air piping shall be deburred, thoroughly cleaned and cuttings removed, before installation.
245. Where welded pipe is connected to removable portions, welded swivel butt flanged fittings shall
be provided at the joints.
246. All piping shall be securely fastened and sheathed with sound insulation as required between
piping and clamps to prevent rattle.
247. Where steel piping passes through holes in the floor, bulkhead or similar structure, the piping shall
be rigidly fastened at the holes or have sufficient clearance to eliminate risk of damage by
abrasion.
248. Where copper tubing passes through holes, the tubing shall be sleeved for protection against
damage by abrasion.
249. Copper tubing, if used in exposed under floor applications, shall be suitably protected using
service proven methods.
250. All tube connections shall be 45 degree flared fittings, conforming to SAE specifications.
251. Copper Clad steel tubing shall not be used.
252. Teflon pipe joint tape sealant shall not be used on air piping.
253. All footplate protective covers over piping runs shall use bolted attachment methods, not
weldments.
254. All valves shall be tagged to indicate the function of each valve.
255. Ball valves shall be supplied on fuel, water, and lubricating oil piping.
256. Valves shall not be placed where they can be used as a step to service other equipment.
257. Where practical, locking handle style valves shall be supplied.
6.9 WIRE AND CABLE
6.9.1 CONDUCTORS
258. Except as otherwise recommended by the Contractor and accepted by the Company, conductors
in all electrical wires and cables, including wires and cables in apparatus furnished by sub-
contractors, shall be stranded soft annealed tinned copper in accordance with ASTM B 33.
259. Stranding and conductor construction shall be in accordance the AAR Standard S-501, except that
sizes required to flex during locomotive operation shall be “extra-flex” to the Contractor’s
recommendation and standard accepted by the Company.
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260. Selection of wire/cable sizes and insulation ratings shall be based on the current carrying capacity,
voltage drop, mechanical strength, temperature and flexibility requirements in accordance with
applicable AAR and NEC specifications.
261. Except for traction current cables, maximum wire current capacity shall conform to the
requirements of Article 310 of the NEC.
6.9.2 INSULATION
262. Except as otherwise specified, wire insulation shall be flame retardant cross linked polyolefin
material, rated 2000 volts for wires carrying nominal voltages higher than 300 volts, and rated 600
volts for wires carrying nominal voltages of 300 volts or less.
263. Wire insulation for high temperature applications (connections to power resistors or for heater
leads, or any other source of heat) shall be abrasion resistant poly-tetra-fluoroethylene Teflon
(PTFE) or the Contractor’s standard reviewed and accepted by the Company shall be used.
264. The insulation for wires within replaceable modular units and electronic apparatus shall be to the
Contractor’s standard, with proven service reliability, as accepted by the Company.
6.10 WIRING
6.10.1 GENERAL
265. Wiring replaced shall be to AAR Standards and Recommended Practices.
266. All wiring replaced outside of electrical cabinets/enclosures/compartments shall be in ducts,
rigid metal conduit or flexible conduit with an IP67 rating and with a proven history in a North
American railroad locomotive environment. Exception will be given to power cables larger than 1
AWG and with insulation thicker than 2.5 mm, with the following conditions:
267. Within the car body, they shall be protected in such a way as to have at least an IP20 rating;
268. Outside of the car body, they shall be protected against flying debris.
269. All wires replaced shall be routed away from areas of heat.
270. Power circuit cables replaced, 60 Hz AC wiring, and low voltage control wiring shall be run in
separate conduits/ducting/wire bundles.
271. All wires in ducts, rigid or flexible conduit instal led shall be routed to avoid being used as a
handhold or footstep.
272. Each wire and cable shall be clearly marked at both ends adjacent to the terminations, with a
unique designation corresponding to the wiring diagram/schematic, with either a permanently
marked sleeve, permanent stamping or an industry acceptable system.
273. All wiring replaced shall be generously supported in such a way that the terminal lug does not
take the weight of the wire and that the insulation is not damaged by the support materials.
274. Support material shall provide an electrical insulating barrier between the wire insulation and the
locomotive car body/frame.
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275. If wire-pulling lubricant is used, it shall be non-conductive, non-hygroscopic, odor-free, and not
attract vermin.
6.10.2 GROUNDING
275. All electrical circuits, except the 120 VAC neutral connection(s) and ground protection
connections, shall be insulated from the locomotive structure.
276. Grounding and bonding connections shall be made through copper or bronze pads, brazed to car
body or as OEM design.
277. All equipment enclosures shall be grounded.
278. Shock mounted equipment shall have flexible, “strap” type grounding leads.
6.10.3 TERMINATIONS
279. Electrical connections shall be screw or nut and stud, with ring lug crimp-on terminals, except for
non-trainline circuits not carrying more than 20 Amps that may use high grade “Fast-On”
terminals. All connections shall resist loosening due to vibration and not require adjustment for
the service life of the locomotive.
280. Heavy-duty compression type wire and cable terminations shall be used, installed with the
manufacturer’s recommended tooling and pressures.
281. Soldered terminations may only be used where reviewed and accepted by the Company.
282. Butt connectors shall not be used under normal circumstances.
293. Service loops (extra wire) shall be provided at all termination points to allow for three renewals of
the terminations, if required.
294. Each terminal board applied shall have spare terminals, at least 10% of the total number,
rounded up to the next whole number, as spares.
6.10.4 UNDERFRAME
295. Neoprene cleats with adequate backing plates shall be used to secure power motor cables
beneath the locomotive frame.
296. Cable runs and conduits shall be free of sharp corners.
297. Cable runs and conduits shall be located clear of access to any under frame equipment.
298. All covers for under frame fittings, pull and junction boxes shall have an IP67 or NEMA4 rating.
299. If threaded fasteners are used to retain covers, they shall be stainless steel.
300. Anchor nuts or retained tap plates, not tapped holes, shall be used with threaded fasteners.
301. All under frame junction boxes shall be weatherproof, shall have provisions for breathing and shall
be connected so that drainage shall not pass through conduit to other locations.
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6.10.5 CONDUITS
302. Conduits shall be installed in such a manner as to avoid moisture ingress and the creation of
locations that trap moisture.
303. Bend radii of rigid conduit shall be as large as possible to facilitate pull through.
304. Rigid conduit bends shall be produced by machine, with smooth surfaces on the inner side of the
bend.
305. Conduit fill by cross-sectional area shall not exceed 30% for two conductors or 40% otherwise. A
multi-conductor jacketed cable is considered to be one conductor for these calculations.
6.10.6 CABINETS AND CONDUIT BOXES
306. Wiring bundles shall be liberally supported and secured by cable ties, tapes and supports, which
shall be flame retardant.
307. All wiring shall be supported to prevent the imposition of undue strain on the terminals.
308. If threaded fasteners are used to retain covers, they shall be used in conjunction with anchor nuts
or tapping plates.
309. Wires entering/leaving electrical cabinets/conduit boxes shall be protected from chafing by a
nipple-bushing arrangement with plastic inserts to protect wiring.
6.11 WELDING
6.11.1 WELDING RESPONSIBILITY
310. The Contractor shall be responsible for the quality of all welding and brazing, including that done
by sub-contractors.
311. Standards for workmanship quality control and design of welding shall be to the Contractor’s
standards, reference to the Canadian Welding Standards by the CWB, or equivalent American
Standards. Welding shall be as per latest revision of ANSI/AWS D15.1 "Railroad Welding
Specification - Cars and Locomotives", except where accepted by the Company.
312. All welders employed in making welds on structure, or products built under this specification, shall
have been tested to determine their proficiency in producing acceptable welds by operation of the
welding equipment used.
6.11.2 WELD PREPARATION
313. Before welding of any sort is started, parts to be joined shall be properly cleaned of all coatings,
and surface contaminants.
314. Any corrosion protection removed for welding shall be replaced after the welding has been
inspected and accepted as satisfactory.
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6.12 PAINTING
315. The entire locomotive shall be washed to be free of oil, grease, dirt and other contaminants. Any
remaining contaminant shall be removed by solvent cleaning prior to painting.
316. Exterior surfaces of locomotive carbody shall receive a commercial blasted.
317. Locomotive underframe, trucks and the interior surfaces of the carbody, including the cab, shall be
blasted.
318. Gouges, pitting’s and crevices on exterior surfaces of the carbody and inside the cab shall be
glazed to obtain a uniform surface prior to painting.
319. All paints shall be cadmium and chromium free and be formulated to resist discoloration caused
by sunlight and UV rays.
320. All paints shall be compatible and of high quality.
321. Exterior car body paint scheme shall be provided by the Company after contract signature.
322. All exterior surfaces of the carbody shall be primed and top coated. An alkyd or epoxy primer shall
be used. The top coat shall be an acrylic, polyester, urethane or polyurethane paint with a
minimum gloss of 65%. The minimum total dry film thickness (DFT) of the primer and top coat
shall be 130 microns.
323. As a minimum, all unprotected surfaces of the underframe, trucks and of the interior of the
carbody, including the cab, shall be primed.
321. The underframe, trucks and buffer beams shall be painted black. An alkyd paint is acceptable. The
final gloss shall be 40% minimum.
322. The interior of the long hood and equipment located in the hood (main generator, engine,
compressor, equipment rack, etc. Shall be painted beige or suede grey. The paint shall be epoxy,
alkyd or acrylic based. A minimum dry film thickness is of 100 microns is required.
323. The interior of the cab and of the nose compartment shall be painted with an epoxy or urethane
paint offering a good wear resistance, with a minimum gloss of 50% shall be applied.
324. Mating surfaces shall be primed prior to mating to prevent the appearance of ‘rust stains.’
325. Exterior car body gloss shall be 65% minimum.
7 TESTING
Upon completion of the overhaul, the Contractor shall conduct the following tests.
7.1 FINAL TEST
326. Check for leaks – water, fuel, lube oil and air systems.
327. Sequence test all circuits.
328. Check all lights.
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329. Perform Load Test for four (4) hours, including at least one hour of continuous operation at full
horsepower – check shutter opening and fan operation.
330. Record all pressure, vacuum and temperature readings. Successful road test shall be performed.
331. Make final movement and running checks.
332. Verify performance control function during load tests.
333. Complete locomotive must meet this specification.
7.2 TEST RUN
334. The finished locomotive shall be track tested before final quality control inspection and shipment.
335. Running tests shall be performed on the Contractor’s Test Track, to qualify air and dynamic
braking, speedometer, vigilance functions, event recorder functions, forward and reverse
operation, cab and wayside noise tests, and multiple unit functions with a second locomotive
336. Following test run, unit shall be given Final Inspection and:
a) Take oil sample for laboratory analysis.
b) Correct all exceptions noted by Quality Control.
7.3 PRE-SHIPMENT INSPECTION
337. Upon satisfactory completion of testing and rectification of any previously rejected details, at the
Contractor’s manufacturing site, the locomotive shall be offered for Pre-Shipment Inspection by
the Company’s QA Representative.
338. The Contractor shall prepare and submit to the Company’s QA Representative a pre-shipment
inspection form.
339. A Preliminary Acceptance Certificate shall be issued by the Company upon satisfactorily
completion of the pre-shipment inspection, clearing the locomotive for shipment the Company’s
site.
7.4 OPTIONAL SITE TESTS
340. Upon delivery of the Locomotives to the Customer’s site, the Contractor in conjunction with the
Customer and/or his representative shall perform static and low speed functional tests to verify
that the locomotive remains in the condition as at the pre-shipment inspection.
341. In addition, the Contractor in conjunction with the Customer and/or his representative shall
perform functional tests of the locomotive coupled to another Locomotive. These shall verify
multiple unit functions and check on MU cables and air hose movements and clearances on turns
and through switches.
Locomotives that fail to satisfactorily pass pre-ship site tests shall be subject to correction of the defects.
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8 QUALITY
8.1 GENERAL
All aspects of executed work shall conform to the M1003 AAR quality process.
8.2 QUALITY ASSURANCE
The Contractor shall develop, implement and maintain a quality assurance system in accordance with
M1003 AAR quality assurance certification process plan acceptable to the Company covering all works
under the Contract, including all of the Contractor’s subcontractors.
The Contractor shall submit a Quality Manual and project Quality Plan at delivery. The Project Quality
plan shall include all Inspection and Test Plans (ITP’s) for the pre-ship work performed.
The Project Quality Plan shall describe the proposed methodology to ensure compliance with their
quality assurance plan. The Project Quality Plan shall list all specific work procedures and systems
proposed for control of the works and shall include all procedures nominated in the ITPs.
Inspection and test plans shall be submitted to cover all manufacturing, erection, and commissioning of
the works. The ITPs shall include the following:
� Description of the work process or activity;
� Identification of the test, procedure or work instruction;
� Witness and hold points;
� Test equipment details required for specified tests; and
� Record management for tests, inspections and trials.
8.3 INSPECTION, HOLD AND WITNESS POINT REQUIREMENTS
Throughout the duration of the Contract, the Contractor shall permit the Company free access to the
works at all times for the purpose of carrying out inspection, monitoring and testing. Any portion of the
work can be rejected at any time prior to the completion of the Contract, where defects have been
found.
As a minimum the inspection and test plans (ITP’s) generated shall include witness and hold points
as per the following.
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Table 4 - Minimum hold and witness point requirements
Hold Point (HP) or Witness Point (WP) (HP /
WP)
Notes
Approval of:
• Document Index & Schedule
• Quality Procedures
• Quality Plan
• Inspection & Testing Plans
•
HP Prior to start of Manufacturing.
Approval of the following drawings and data
• Cab layout
• Locomotive general arrangement drawing
• Locomotive traction control system functional
specification
HP Refer to “Drawings and Data
Requirements” section.
Shop Assembly
Witness shop assembly of complete components,
where final assembly is larger than the transport
window, prior to disassembly for transport
-
Factory acceptance testing
Witness factory acceptance testing.
Witness final load test
WP
Final Inspection
Visual inspection for compliance with purchase order
and specification requirements.
Verify documentation status to allow release for
transport.
WP
Packaging for shipment
Verify adequacy of packaging and marking for
transport.
WP
Performance acceptance testing WP
Verify Locomotives against key design parameters
during Site Acceptance Tests (SAT).
9 SPARES
The Contractor shall provide a list of recommended spare parts to maintain the Locomotive for a
period of two (2) years along with pricing per item for the Company’s assessment.
10 SPECIFIC PACKING, HANDLING TRANSPORT AND
STORAGE REQUIREMENTS
Special packaging provisions are available upon request.
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11 DRAWING AND DATA REQUIREMENTS
11.1 GENERAL
The Contractor shall submit available OEM drawings, schematics, or data in accordance with the
"Document index and Schedule”, including any specified in this Schedule.
Optional text in all final deliverables for engineering and design, data, drawings, technical
information, reports and computations shall be dual translated into customer specific languages.
Abbreviations shall only be permitted as approved by the Company.
11.2 SUBMISSION AND REVIEW
The Contractor shall ensure that all drawings and data are checked and signed as checked for accuracy,
clarity, completeness and conformance with the applicable codes, standards and specifications before
they are submitted to the customer upon delivery.
11.3 OPTIONAL DRAWINGS AND DATA
The Contractor shall prepare and maintain a master list of all drawings and data to be prepared in
the performance of the Works. The list shall include the following details:
� Number;
� Title;
� Revision;
� Size;
� Type (e.g. drawing, calculation, etc);
� Progress percent complete; and
� Date for submission to the Company (if applicable).
All drawings submitted shall be legible in detail and of high quality to allow reproduction in the
applicable sizes.
All company generated drawings will be marked ‘As-Built’ unless otherwise directed by the Company.
The Company shall provide electronic copies of the optional project title blocks for duplication by the
Customer as needed. Project drawing numbers shall also be provided by the Company.
11.4 SCHEDULE OF DRAWING AND DATA REQUIREMENTS
The Contractor shall submit any optional drawings/schematics and documents/at delivery.
Drawings shall be presented as described in 11.3.
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12 WARRANTY
12 Months export warranty is included.
a. Includes all components.
b. Does not include labor
Warranty Certificate available upon request.