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California Department of Transportation Division of Rail Rolling Stock Procurement Branch California Department of Transportation Division of Rail Rolling Stock Procurement Branch Fabricated Truck and Ride Quality Performance and Evaluation Criteria Specification 5-102 Revision A May 11, 2010 California Department of Transportation Specification 5-102 Rolling Stock Procurement Branch Fabricated Truck and Ride Quality Rev. A Table of Contents 1.0 Fabricated Truck Performance ..................................................................... 4 1.1 Regulations, Standards, Specifications and Drawings ............................... 4 1.1.1 Regulations ......................................................................................... 4 1.1.2 Standards ........................................................................................... 4 1.1.3 Specifications ...................................................................................... 5 1.1.4 Drawings ............................................................................................ 5 1.1.5 General ............................................................................................... 5 1.1.6 Weights, Dimensions and Clearances ................................................... 5 1.1.7 Truck Frame and Components ............................................................. 6 1.1.8 Wheel and Axle Assembly .................................................................... 6 1.1.9 Wheels ................................................................................................ 6 1.1.10 Axles ................................................................................................... 6 1.1.11 Wheelset Balancing ............................................................................. 6 1.1.12 Journal Bearings ................................................................................. 7 1.1.13 Speed Sensors and Cables ................................................................... 7 1.1.14 Wheelset Records ................................................................................ 8 1.1.15 Truck Braking System ......................................................................... 8 1.1.16 Handbrake .......................................................................................... 8 1.1.17 Wheel Slip Protection System ............................................................... 9 1.1.18 Suspension ......................................................................................... 9 1.1.19 Longitudinal Traction Rods ................................................................ 10 1.1.20 Strength of Truck to Car Body Connections ........................................ 10 1.1.21 External Noise Limit .......................................................................... 11 1.1.22 Electrical Grounding ......................................................................... 11 1.1.23 Reliability and Maintainability ........................................................... 11 1.1.24 Ride Quality ...................................................................................... 12 1.1.25 Modeling ........................................................................................... 13 1.1.26 Dynamic Modeling ............................................................................. 13 1.1.27 Truck Frame Fatigue Modeling ........................................................... 21 1.1.28 Operating Environment Considerations .............................................. 21 1.1.29 Truck Frame/Bolster Fabrication ....................................................... 21 1.1.30 Static and Fatigue Tests .................................................................... 23 1.1.31 Service Life and Maintenance Requirements ....................................... 23 Appendix A .................................................................................................... 24 2.0 Fabricated Truck Evaluation Criteria ......................................................... 25 2.1 Regulations, Standards, Specifications and Drawings ............................. 25 2.1.1 Regulations ....................................................................................... 25 2.1.2 Standards ......................................................................................... 25 2.2 Track Worthiness .................................................................................. 26 2.2.1 Hunting Test ..................................................................................... 26 Page 2 of 34 California Department of Transportation Specification 5-102 Rolling Stock Procurement Branch Fabricated Truck and Ride Quality Rev. A 2.2.2 Constant Curving Test ....................................................................... 27 2.2.3 Spiral Test ........................................................................................ 27 2.2.4 Twist and Roll Test ............................................................................ 27 2.2.5 Pitch and Bounce Test ....................................................................... 28 2.2.6 Yaw and Sway Test ............................................................................ 28 2.2.7 Dynamic Curving Test ....................................................................... 28 2.3 Static Body Roll ..................................................................................... 29 2.4 Physical Testing .................................................................................... 29 2.4.1 Static Testing .................................................................................... 30 2.4.2 Fatigue test ....................................................................................... 31 2.5 Ride Quality Testing .............................................................................. 32 2.6 Braking Performance Test ...................................................................... 33 2.7 Exterior Noise Level Testing ................................................................... 34 2.8 Manufacturing and Production Testing ................................................... 34 Page 3 of 34 California Department of Transportation Specification 5-102 Rolling Stock Procurement Branch Fabricated Truck and Ride Quality Rev. A 1.0 Fabricated Truck Performance 1.1 Regulations, Standards, Specifications and Drawings All regulations, standards, specifications, and drawings, which pertain to this chapter, are listed below. The following list is furnished as a guide to the truck supplier, but shall not be construed as complete. When any of the following are superseded by an approved revision the revision shall apply. 1.1.1 Regulations FRA (Federal Railroad Administration) 49CFR 213 Subparts A – G 49CFR 238.427 1.1.2 Standards AAR (Association of American Railroads) Manuals of Standards and Recommended Practices M-101: Axles, Carbon Steel, Heat-Treated M-107/208: Wheels, Carbon Steel M-114: Helical Springs, Heat Treated Steel M-213: Truck – Fabricated Steel Design M-1001, Chapter 11: Service-Worthiness Tests and Analyses for New Freight Cars S-2026: Plate B Unrestricted Interchange S-3007: Specifications for the Certification of New Truck Designs for Compatibility with Hot Bearing Detection Systems APTA (American Public Transportation Association) SS-M-006-98: Standard for Parking Brakes for New Passenger Locomotives and Cars SS-C&S-034-99: Standard for the Design and Construction of Passenger Railroad Rolling Stock RP-M-009-98: Recommended Practice for New Truck Design ASTM (American Society for Testing and Materials) E94-04: Standard Guide for Radiographic Examination E709-01: Standard Guide for Magnetic Particle Inspection AWS (American Welding Society) AWS D15.1: Railroad Welding Specification – Cars and Locomotives European Standards EN13260:2003 Railway Applications – Wheelsets and Bogies – Product Requirements VDI 2230: An Introduction to the Calculation Method for Determining the Stress in a Bolted Joint Page 4 of 34 California Department of Transportation Specification 5-102 Rolling Stock Procurement Branch Fabricated Truck and Ride Quality Rev. A ISO (International Organization for Standardization) ISO 2631-1: Mechanical Vibration and Shock – Evaluation of Human Exposure to Whole Body Vibration. Part 1: General Requirements ISO 2631-4: Mechanical Vibration and Shock – Evaluation of Human Exposure to Whole Body Vibration. Part 4: Guidelines for the Evaluation of the Effects of Vibration and Rotational Motion on Passenger and Crew Comfort in Fixed Guideway Transport Systems ISO 10326-2:2001(E): Mechanical Vibration – Laboratory method for evaluating vehicle seat vibration – Part 2: Application to Railway Vehicles 1.1.3 Specifications Amtrak Specification 664: Anti Wheel Slide System 1.1.4 Drawings Amtrak D-08-2269: Axle Single Level Program 1.1.5 General The truck design shall be of a technology and design proven in revenue passenger service in North America or elsewhere that has been operating on North American standard gauge track at speeds up to 125 mph. The truck can also be a new design but not withstanding, the supplier will need to demonstrate their fitness for use in meeting this specification. The design shall incorporate two axles per truck, with outside axle bearings and a truck wheelbase range of 8 ft – 2.5 in. to 8 ft – 6 in. Provisions shall be made for adjusting the car body height up to 2 in. to compensate for wheel wear or other height variations. The adjustments shall be made without de-trucking the car. 1.1.6 Weights, Dimensions and Clearances
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