attachment 1 ve 15-044 mbta drawings, miscellaneous … for this overhaul program. this attachment...

Attachment 1 Technical Specification No. VE 15-044 for New Flyer Low Floor ECD (Option Fleet) Buses

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ATTACHMENT 1

VE 15-044

MBTA Drawings, Miscellaneous Technical Information,

Color & Paint Scheme, and Decals & Special Signage

Massachusetts Bay Transportation Authority Vehicle Engineering Boston, Massachusetts


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The following details the paint color, paint scheme, and decals (interior and exterior) required for this overhaul program. This attachment includes the following:

1) Color and paint scheme drawings

2) Original decal scheme drawings (interior and exterior)

3) Decal, signage and placard listings and specifications: List of new decals and special signage, including identification of decals to be converted to placards.

The enclosed original decal layout drawings are for reference purposes only, reflecting the decal layouts (interior and exterior) as the vehicles were originally delivered to Boston. The decal/signage configuration has been modified since that time. Available existing decals will be provided to the Contractor at the first pre-production meeting. The Authority is currently in the midst of upgrading their vehicle signage and graphics in response to accessibility signage and quality improvements. Also, some interior decals are to be replaced with placards to improve durability. The updated decals description/listings, as currently envisioned, are listed in item 3. Placard designs / samples shall be submitted to the Authority for review and approval as part of the Engineering Design Review process. The final decal configuration shall be discussed and finalized during the design review process. Additional or modified decals/signage, if required, will be recognized as additional cost items.

(Attach Paint Scheme & Decal Drawings and Pics of needed Placards)


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ATTACHMENT 2

VE 15-044

New Flyer Open Instruction to Service (ITS) Campaign Work Scope


Attachment 2 Technical Specification No. VE 15-xxx for New Flyer Low Floor ECD (Option Fleet) Buses

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Attachment 2 New Flyer Open ITS

Structural Campaigns Scope of Work

The 155 New Flyer ECD (Option) fleet have accrued several New Flyer warranty campaigns that have not yet been completed. To date there are five (5) outstanding New Flyer Instruction To Service (ITS) campaigns. In line with Section 2.2.1.2.1 of the Technical Specification, the Contractor shall perform these campaigns on all buses during the overhaul process. These campaigns consist of the following:

• ITS 4577 – Engine Strut o Part A – Inspect engine area for additional cracks/damage o Part B – Replace engine strut hardware o Part C – Repair crack in engine compartment shelf with 2”x 2” angle gusset o Part D – Replace trans cooler reservoir bracket

• ITS 4775 – Repair Radiator Support Plate

o Repair cracked weld/ install new support plate at street side firewall below Radiator/CAC

• ITS 4850 – A/C Compressor Bracket Repair o Weld repair crack on bracket below A/C Compressor

• ITS 4863 – A/C Compressor Base Plate

o Remove and replace AC Compressor base support

• ITS 5081 – Fuel Filter Bracket o Remove and replace fuel filter bracket

The following is a list of parts needed to complete each ITS:

ITS 4577

ITEM # ITEM DESCRIPTION QTY PER COACH 10B08028 Bolt, Hex ½ UNC X 1.75 4

811008 Washer, Trans Cooler 4 30W08000 Washer, Lock Hel ½ NOM 4

211953 Strip, Bumper Isolator 2 10B12040 Bolt, Hex ¾ UNC X 2.50 2 11N12000 Nut, Hex ¾ UFC 2 20W12000 Washer, Flat ¾ 8 21N12000 Nut Hex Jam ¾ 2


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40N12000 Nut, Hex Lock ¾ UNC 2 10W06000 Washer, Flat 3/8 NOM 10 10B06016 Bolt 3/8 X 1.00 6 30W06000 Washer, Lock 3/8 NOM 2 40N06000 Nut, 3/8 – 16 Lock 4

434466 Plate, Rework SST 1 288197 Assy., Bkt. Trans Reservoir 1 5928660 Never Seize 0.1

ITS 4775

ITEM # ITEM DESCRIPTION QTY PER COACH 20W07000 Washer, Hardened 7/16 8 40N07000 Nut Lock 7/16 - 14 4 10B07020 Bolt, Hex 7/16 UNC X 1.25 4

453032 Bracket, Rad Channel End 1 235584 Undercoat, PPG 7972-W 0.01

ITS 4850

ITEM # ITEM DESCRIPTION QTY PER COACH 263918 Gusset 1 235584 Undercoat, PPG 7972-W 0.01

ITS 4863

ITEM # ITEM DESCRIPTION QTY PER COACH 252249 Assy., A/C Comp Base Supp. 1

40N08000 Nut, Hex Lock ½ NC 8 40N07000 Nut Lock 7/16 - 14 6 40N12000 Nut Lock Nylon ¾” 10 NC 2 5928660 Never Seize 0.01

ITS 5081

ITEM # ITEM DESCRIPTION QTY PER COACH 483029 Bracket, Filter Fuel 1

10W06000 Flat Washer .38 NOM 4 10B06020 Bolt, Hex 3/8 UNC X 1.25 2 40N06000 Nut, Hex Lock 3/8 UNC 2 10B04012 Bolt, Hex ¼ UNC X 0.75” 2 10W04000 Washer Flat ¼ 4


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40N04000 Nut, Hex Lock ¼” 2 322770 Bracket, Support Filter Fuel 1

The Contractor shall inspect all buses and perform the outlined ITS campaigns in accordance with the New Flyer work instructions. The Contractor shall also create and maintain a tracking matrix to verify all ITSs have been performed on all 155 buses, and provide the tracking matrix to the Authority.

As part of a prior agreement with the Authority, New Flyer Industries has agreed to review and approve work performed on the Pilot vehicle. New Flyer approval of all ITS work must be obtained and documented by the Contractor as part of the Pilot Bus Program in order to confirm appropriate procedures are established for the duration of the program. The Contractor is responsible for coordinating this support with New Flyer Industries.

The detailed outstanding ITS campaigns are attached below with permission from New Flyer Industries.

(ATTACH ITSs TO DOCUMENT)


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ATTACHMENT 3

VE 15-044

Fluids Listing



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Fluids – MBTA New Flyer ECD

Fluid Description Manufacturer

Diesel Engine Oil Shell Rimula Super 15W40 Shell

Transmission Fluid TranSynd 295 BP

Synthetic Differential Oil Delvac Synthetic Gear Oil (75W-90) Mobil

Anti-Freeze Fleet Charge 50/50 Old World Industries

Power Steering Fluid Kendal Versa – Tran ATF Conoco Phillips

(Factory Fill – Dextron III)

Grease Lithium Complex Hi Temp EP 2


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ATTACHMENT 4

VE 15-044

Tracking and Request Forms


MBTA Bus No.:Prod. Bus No.:

Labor Rate:

Hidden Damage

Item Description of Work Qty.iscreet List # Material Cost Markup Total Mat'l

abor hrs Labor Cost Total Cost Date Entered Date Submitted

ate Approved

1246789

1011121314151617181920212223242526272829

Sub-total Discreet HD $0.00 $0.00 $0.00 0.0 $0.00 $0.00

#REF!

Date

New Flyer ECD Overhaul - Hidden Damage Tracking

MBTA Signature - Approval / Rejection

MBTA Bus No.:Prod. Bus No.:

Date:Line Item:

Initiated By:

Description of Work:

MBC Part No OE

OE Part No. (If appl icable) Description Cost Hours

0.0

Mat'l Cost -$ Labor Hours 0.0

Material Cost -$ Labor Hrs 0.0Markup -$ Labor Rate -$ Total Mat'l -$ Labor Cost -$

Total Cost -$

Work Approved

Work Rejected

DateMBTA Signature - Approval / Rejection

Description

New Flyer ECD Overhaul - Hidden Damage Approval Form

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MBTA IFB CAP XX-XXX New Flyer ECD Major Component Tracking

Request No.:

Date:

OEM Part Number

OEM Part Number

Request Approved

Request Rejected

Date

New Flyer ECD Overhaul - Request for Approved Equal Form

Bus System(s) Impacted:

Reason for Request:

MBTA Signature - Approval / Rejection

OEM Part Information:

Description

Proposed Equal Part Information:

Description of Changes (dimensional, material, etc.):

Supporting Documentation Attached:

Description

New Flyer ECD Overhaul - Request for Approved Equal (RAE) Tracking

Date:

RAE No. Submittal

Letter Date

Submitted Description of Change / System(s) Impacted Approved/Rejected

Response Letter Date of Response

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19


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ATTACHMENT 5

VE 15-044

Thermo King HVAC System Overhaul

Work Scope



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Attachment 5

Thermo King HVAC System Overhaul

1.0 HVAC System and Rehab Description

The 155 2007/2008 New Flyer (ECD) 40” city transit buses operated by MBTA are currently equipped with the Thermo King Model T11-M58B rear mounted air conditioning system and Model X430 compressor & clutch assembly utilizing R22 refrigerant. TK System No. Description 900065 TK Model T11-M58B A/C System Each consists of: Qty TK No. Description 1 XXXXXX Model T11-M58B Condenser/Evap Unit, Rear Mount 1 720549 Model X430 Compressor & Clutch Assembly TK Reference Manuals Model T11-M58B Maintenance Manual: TK Form No. 51400-3-MM Model T11-M58B Parts Manual: TK Form No. 51405

1.1 The Model T11-M58B rear mounted air conditioning system shall be inspected, serviced,

and repaired utilizing Thermo King’s Annual Bus Air Conditioning Preventative Maintenance C Inspection (TK Form No. 40812-1) along with the TK Model T11-M58B maintenance manual (TK Form No. 51400-3-MM) to ensure proper A/C system operation. A copy of the TK A/C inspection form is attached at the end of this specification (Reference: Attachment A). The TK Model T11-M58B rear mount A/C System maintenance manual should be obtained from Thermo King.

All TK Model T11-M58B A/C unit components shall be thoroughly inspected for

condition and functionality. Any components which are damaged, non-functioning, or significantly degraded shall be brought to the attention of the Authority’s Resident Inspector and addressed as Hidden Damage.

It is anticipated that the refrigerant in all 155 buses will be converted from R22 to R407c

prior to the commencement of this overhaul project.


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1.2 The Contractor shall remove the existing Model X430 compressor and clutch assembly (TK P/N 720549 – R22) from the bus and replace it with a complete new Thermo King OEM Model X430 compressor and clutch assembly (TK P/N 703406 – R407c). This X430 compressor assembly is to include new clutch assembly, HPCO switch (500psig), LPCO switch (5-17 “hg), 3/8” flare service access fittings (R407c), POE oil, discharge temperature sensor and wire harness assembly. The Model X430 compressor and clutch assembly shall have a one year warranty.

1.3 At a minimum, the following components are to be replaced with new Thermo King

OEM parts:

1. X430 Compressor Kit Assy. Including: a. Full Clutch Assy. b. Suction & Discharge Service Valves c. Pressure Switches d. 3/8 Port Fittings

2. A/C compressor drive belt 3. Compressor oil (4 liters) 4. Evaporator motor 5. Coupling, Evap Motor 6. Bearing flange 7. Hose-Silicone 8. Clamp-spring 9. Expansion valve 10. Receiver tank & tubing assy.

a. Receiver tank assy. b. Receiver outlet tube c. Receiver inlet tube d. Saddle fitting

11. Relief valve, receiver tank 12. O-ring, relief valve 13. Equalizer tube 14. Drier 15. Drier to expansion inlet tubing assy.

a. Shut off valve b. Bushing c. Tube d. Brazed shoulder e. Shoulder nut f. Valve to sight glass tube g. Liquid indicator


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16. Solenoid repair kit 17. Solenoid coil 18. Refrigeration hose - Suction 19. Refrigeration hose – Discharge 20. Discharge pressure gauge 21. Suction pressure gauge 22. Tube Discharge – Gauge to bulkhead 23. Tube Suction – Gauge to bulkhead 24. Tube – Valve to fitting 25. Adapter 26. Flat washer 27. Nut 28. Coupling 29. Grommet 30. Electronic drive module 31. Standard display assy. 32. Temperature sensor

a. Coil temp. b. Water temp. c. Return air

33. Ambient temperature sensor 34. Harness #2 – fuse block cable 35. Pressure switch – Condenser fan speed 36. Module - Intelligaire II 37. Circuit breaker 38. Jumper 39. Fuse holder 40. Fuse (10Amp) 41. Fuse (15Amp) 42. Drain tubes 43. Clamp – drain tube 44. Check valve 45. Return air filter 46. Evaporator cover – Complete 47. Hardware – Evaporator cover 48. Decal – R407c 49. Decal – TK 50. Decal – Caution 51. 2ND Generation Brushless Conversion Kit


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1.4 While the air conditioning evaporator coils, condenser coils, and refrigerant tubing are open, they shall be purged with dry nitrogen to any remove residual dirt/refrigerant oil. Once the A/C system is reassembled, it shall be leak checked, evacuated and charged with 17.3 lbs. of new 407c refrigerant utilizing the procedure outlined in the TK Model T11-M58B Maintenance Manual. The A/C system shall be run tested per Thermo King air conditioning system pre-delivery inspection procedures to ensure proper A/C system operation (Ref: TK Form No. 40136). Thermo King shall approve of the pilot bus rehab process and procedures.

1.5 The Contractor shall supply eight (8) Thermo King R407c refrigerant service gauge manifold sets, with fittings consisting of: Qty TK Service Part No. Description 1 204-1925 Service Gauge Manifold Set – R407c Refrigerant 2 204-0734 Hose, Service – 48” Long, Heavy Wall Black Evacuation Grade Hose with 3/8” FFL Swivel Fitting x ¼” FFL

Swivel Fitting 2 51-2105 Fitting, Reducer, 3/8” MFL x ¼” FFL 1 204-0763 Hose, Service – 72” Long, Yellow Charging Hose with ¼” FFL Swivel Fitting x ¼” FFL Swivel Fitting 1.6 Also, as part of the overhaul, a 2ND Generation Brushless Condenser Motor Upgrade kit

shall be installed. The following components are included in the upgrade kit, and are to be installed:

TK Part # Description

xxxxxx Brushless Cond Fan & Motor Assy. xxxxxx Wire Harness xxxxxx Fan Support Bracket xxxxxx Ground Stud Assy. xxxxxx Structural Modification Template xxxxxx 2 Hole Liquid Tight Insert xxxxxx Liquid Tight xxxxxx Tab Motor Hold-down xxxxxx Weld Nuts xxxxxx Pop Rivets

(Insert TK 2ND Gen Brushless Motor Upgrade Kit Installation Procedure Here)


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Thermo King Corporation bus A/C technical representative shall perform a HVAC system installation and applicable review of the contractor’s HVAC rehab process and procedures on the pilot bus and provide a written application approval. The bus rehab contractor shall provide a signed copy of the Thermo King bus A/C system pre-delivery inspection (TK Form No. 40136) for each completed bus rehab. As part of the Engineering Design Review process, the Contractor is responsible for submitting a detailed HVAC system overhaul package. This package shall include qualification information and specific overhaul procedures.


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ATTACHMENT 6

VE 15-044

Minuteman Camera System

Work Scope



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Attachment 6 Minuteman Camera System

Scope of Work The 155 New Flyer (Option Order) ECD buses were originally equipped with a Safety Vision camera monitoring systems. The Authority plans to install a new Minuteman Security camera system as part of a separate effort. As part of this overhaul program, the Contractor shall install appropriate wiring harnesses and related upgrades to prepare the vehicles for the new camera system. In line with Section 2.3.6.7 of the Technical Specification, the Contractor shall:

• Remove the existing camera system from the vehicles, including but not limited to: o All Safety Vision cameras o Wiring harnesses o Recording equipment o All associated hardware

• Return all Safety Vision equipment to the Authority • Properly install and secure all new wiring harnesses required for the installation of the

Minuteman Security camera system Due to the camera system being installed at a later date by the Authority, and not as part of this program, the Contractor shall also install appropriate protective / cosmetic “blank” plates over wiring harness locations. The wiring harnesses must be installed to Minuteman Security OEM specifications, and Minuteman OEM parts shall be used. At a minimum, the following wiring harnesses and components shall be installed to accommodate the future upgrade to the Minuteman Camera System:

ITEM # ITEM DESCRIPTION QTY


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As part of the Pilot Bus program, the Contractor shall work with Minuteman Security to develop appropriate installation procedures including the definition of camera locations. In addition, the Contractor shall work with Minuteman Security to develop an appropriate test procedure and testing modules to validate the installation of harnesses as part of the vehicle testing / inspection process. As part of the Engineering Design Review process, the Contractor is responsible for submitting a detailed Minuteman Security camera system wiring installation package. This package shall include all specific installation and testing procedures.


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ATTACHMENT 7

VE 15-044

New Flyer Battery Management System



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Attachment 7 New Flyer Industries

Battery Management System Scope of Work

To increase the longevity of the vehicle batteries, all 155 New Flyer ECD buses will be retrofitted with the integration of the New Flyer “Battery Management System”. In line with Section 2.3.6.5 of the Technical Specification, the Contractor shall retrofit all buses with New Flyer’s “Battery Management System”, and test for functionality. Battery Management System “Installation Kits” supplied by New Flyer Industries must be used. These Kits will consist at a minimum of the following items required for installation:

ITEM # ITEM DESCRIPTION QTY

The Contractor will coordinate with New Flyer all needed support for the retrofit and will obtain New Flyer installation approval on the Pilot Bus. As part of the Engineering Design Review process, the Contractor is responsible for developing and submitting a detailed New Flyer Battery Management System installation and test procedure.

attachment 1 ve 15-044 mbta drawings, miscellaneous … for this overhaul program. this attachment...

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