Three years behind schedule, the $81 million worth of double-decker train cars once trumpeted as a turning point in Maryland rail commuting have become so mired in construction problems that it is uncertain when they might roll.
Kawasaki Rail Car Co. of Yonkers, N.Y., won the state contract to build the cars five years ago, promising to deliver the first coaches in ready-to-run condition in January 1997.
But a string of troubles has affected the project. State Mass Transit Administration officials sought the removal of Kawasaki's project manager, have threatened to exact millions of dollars from the company in penalties and are preparing for a possible lawsuit.
"This has been a less than pleasant experience," said Ron Freeland, the agency's administrator. "We're not happy with the delays. Obviously we've had some difficulties. But I'm confident that when we've worked all the kinks out, we'll have excellent cars."
The first cars arrived in March only to fail speed tests. The cars must run smoothly at 120 mph, while these experienced vibrations at 113 mph. The next tests won't be conducted until fall. MTA officials say the cars won't be running until the end of the year at the earliest.
The MTA, which oversees the Maryland Rail Commuter (MARC) system, has refused to formally accept any of the cars until they run properly.
In a telephone interview yesterday, John Lehman, who took over managing the project for Kawasaki a year ago, said: "We'd rather not make any statement at this time."
Other Kawasaki officials did not return phone messages.
The contract for the double-decker cars represented the largest expansion of the MARC fleet when it was approved in 1994.
Each of MARC's 100 coaches seats 80 to 100 people. The 50 new bilevel cars will seat about 132 each and feature more amenities, such as reclining seats, bigger windows and carpeting.
The ability to carry so many more passengers without adding cars or engines or extending station platforms was viewed as a significant and potentially cost-saving benefit as officials eyed the expected growth in mass transit riders.
Kawasaki-built trains of this sort have run flawlessly in Boston.
According to state documents and interviews with state officials, the snags in the Maryland job emerged early and haven't stopped: material shortages, design and quality problems and allegations of poor management at Kawasaki.
