Spek Tek Lokomotif Iran

Technical Specification of Freight Locomotive for Iran Railway

(DF8BI)

CSR QISHUYAN LOCOMOTIVE CO., LTD. Feb. 2009

Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.

CONTENT

DISCLOSURE NOTICE .................................................................................. 1

DECLARATION ........................................................................................... 2

BASIC PRINCIPLE ......................................................................................... 3

1 GENERAL DESCRIPTION .......................................................................... 4

1.1 OVERVIEW ....................................................................................... 4

1.2 GENERAL LAYOUT ............................................................................. 6

1.3 LOCATION OF APPARATUS.................................................................. 8

2 GENERAL DATA ....................................................................................... 12

2.1 KEY TECHNICAL CHARACTERISTIC..................................................... 12

2.2 KEY TECHNICAL DATA ...................................................................... 13

2.3 KEY BASIC TECHNICAL DATA OF LOCOMOTIVE..................................... 14

2.4 TECHNICAL DATA OF KEY PARTS OF LOCOMOTIVE ............................... 16

3 PERFORMANCE ....................................................................................... 28

3.1 HORSEPOWER................................................................................ 28

3.2 TRACTION PERFORMANCE............................................................... 29

3.3 BRAKE PERFORMANCE.................................................................... 29

3.4 HAULING CAPACITY OF LOCO AGAINST DIFFERENT GRADIENTS .......... 32

4 CAR BODY ......................................................................................... 34

4.1 OVERVIEW ..................................................................................... 34

4.2 UNDER-FRAME ............................................................................... 34

4.3 SIDEWALL ...................................................................................... 34


4.4 DRIVER CAB................................................................................... 34

4.5 ELECTRIC APPARATUS ROOM ........................................................... 35

4.6 POWER ROOM ................................................................................ 35

4.7 COOLING ROOM.............................................................................. 36

4.8 AUXILIARY ROOM ............................................................................ 36

4.9 FUEL TANK ..................................................................................... 36

4.10 WASTE RETENTION TANK .............................................................. 37

4.11 ROOF ACCESS LADDER .................................................................. 37

4.12 HANDRAILS AND STEPS.................................................................. 38

4.13 DOORS & DOOR STOPS ................................................................ 38

4.14 LIFTING/JACKING .......................................................................... 38

4.15 ROOF .......................................................................................... 38

4.16 SIDE SHUTTER.............................................................................. 39

4.17 EAVES ......................................................................................... 40

4.18 CONVENIENCE OF MAINTENANCE ................................................... 40

4.19 COUPLER..................................................................................... 40

4.20 BUFFER ....................................................................................... 40

4.21 MAJOR MATERIAL OF THE CAR BODY ............................................... 42

5 BOGIE ......................................................................................... 44

5.1 OVERVIEW ..................................................................................... 44

5.2 BOGIE CONSTRUCTION .................................................................... 45

5.3 BOGIE FRAME................................................................................. 45

5.4 AXLE BOX....................................................................................... 47

5.5 WHEEL SET .................................................................................... 48

5.6 MOTOR SUSPENSION GEAR.............................................................. 49

5.7 GEAR AND GEAR COVER .................................................................. 50

5.8 SIDE BEARING ................................................................................ 50


5.9 FOUNDATION BRAKE RIGGING........................................................... 51

5.10 DRAW GEAR ................................................................................. 54

5.11 FLANGE GREASER ......................................................................... 54

5.12 DAMPER ...................................................................................... 55

5.13 ACCESSORIES .............................................................................. 56

6 AIR SYSTEM AND BRAKE ....................................................................... 58

6.1 OVERVIEW ..................................................................................... 58

6.2 AIR SUPPLY SYSTEM....................................................................... 58

6.3 AIR BRAKE SYSTEM ........................................................................ 60

6.4 SANDING SYSTEM ........................................................................... 62

6.5 AIR HORN SYSTEM .......................................................................... 63

6.6 WINDSHIELD WIPER SYSTEM ............................................................ 64

6.7 CONTROL AIR SYSTEM .................................................................... 65

6.8 HAND BRAKE SYSTEM..................................................................... 65

7 DIESEL ENGINE........................................................................................ 68

7.1 OVERVIEW ..................................................................................... 68

7.2 LUBRICATING OIL SYSTEM................................................................ 71

7.3 FUEL SYSTEM ................................................................................. 72

7.4 INJECTOR....................................................................................... 73

7.5 COOLING WATER SYSTEM ................................................................ 74

7.6 MAIN FRAME ASSEMBLY ................................................................... 76

7.7 CRANKSHAFT ASSEMBLY.................................................................. 77

7.8 CONNECTING ROD ASSEMBLY........................................................... 77

7.9 CAMSHAFT ASSEMBLY ..................................................................... 78

7.10 PGMV GOVERNOR ....................................................................... 79

7.11 TURBO CHARGE SYSTEM................................................................ 80


7.12 MAIN CHARACTERISTIC CURVES OF ENGINE..................................... 83

7.13 OTHER MAIN PARTS OF ENGINE ...................................................... 86

8 AUXILIARY SYSTEM................................................................................. 92

8.1 OVERVIEW ..................................................................................... 92

8.2 AUXILIARY TRANSMISSION SYSTEM ................................................... 92

8.3 VENTILATION SYSTEM ..................................................................... 92

8.4 AIR FILTER SYSTEM ......................................................................... 93

8.5 LUBRICATING OIL FILTER .................................................................. 94

8.6 OIL HEAT EXCHANGER ..................................................................... 95

8.7 RADIATOR ...................................................................................... 96

8.8 FUEL PUMP..................................................................................... 96

8.9 COOLING FAN ................................................................................. 97

8.10 EXPANSION TANK .......................................................................... 98

9 ELECTRIC DRIVE, ELECTRIC CONTROL SYSTEM AND SAFETY APPARATUS ....................................................................................... 101

9.1 OVERVIEW ................................................................................... 101

9.2 SYNCHRONOUS MAIN GENERATOR................................................. 101

9.3 MAIN SILICON RECTIFIER............................................................... 101

9.4 TRACTION MOTOR ........................................................................ 102

9.5 REVOLUTION SPEED TRANSDUCER ................................................ 104

9.6 TRACTION CONTROL SYSTEM ........................................................ 105

9.7 ADHESION CONTROL SYSTEM ........................................................ 106

9.8 SANDING CONTROL....................................................................... 106

9.9 PROTECTION AND POWER DECREASE SYSTEM................................ 106

9.10 BATTERY.................................................................................... 107

9.11 CONTROL SYSTEM ...................................................................... 108

9.12 DEAD MAN DEVICE .......................................................................115


9.13 MULTIPLE UNIT OPERATION FUNCTION............................................115

9.14 DYNAMIC BRAKE DEVICE...............................................................116

9.15 DATA OUTPUT FUNCTION...............................................................116

10 DRIVER CAB AND ACCESSORY EQUIPMENT................................... 123

10.1 OVERVIEW ................................................................................. 123

10.2 CHAIRS...................................................................................... 124

10.3 WINDOWS AND GLASS................................................................. 124

10.4 DOORS AND DOOR SECURITY ...................................................... 124

10.5 HVAC SYSTEM .......................................................................... 125

10.6 FLOORS ..................................................................................... 126

10.7 CEILINGS ................................................................................... 126

10.8 SOUND & HEAT INSULATION PERFORMANCE.................................. 126

10.9 COAT HOOKS ............................................................................. 127

10.10 SIGNAL FLAG BOX .................................................................... 127

10.11 FIRE EXTINGUISHERS ................................................................ 127

10.12 REFRIGERATOR ........................................................................ 127

10.13 REARVIEW FUNCTION ................................................................ 127

10.14 FOLDER SEAT ........................................................................... 128

11 PAINTING ....................................................................................... 129

11.1 SURFACE TREATMENT.................................................................. 129

11.2 VARIETY AND COLOR OF THE PAINT................................................ 129

12 STANDARDS ....................................................................................... 131

12.1 GENERAL ................................................................................... 131

12.2 STANDARD LIST .......................................................................... 131

13 VENDORS LIST OF MAIN WEARABLE PARTS.................................. 133


14 MAJOR SUPPLIER INFORMATION...................................................... 135


DISCLOSURE NOTICE

This document includes proprietary information of CSR Qishuyan Locomotive Co.,

Ltd. (hereinafter as QS), so it is only for the purpose of evaluation by potential

clients. Neither this document nor the any information of the document herein may

be, duplicated, disclosed to other parties or used for any other purpose without

the prior written permission of QS.

Potential clients should abide by the foregoing since the receipt of the document.

Thanks for your cooperation.

CSR QISHUYAN LOCOMOTIVE CO., LTD.


DECLARATION

In order to ensure the main performance of locomotive to meet the requirement of

contract, QS reserves the right of adjusting some parameters, components and

parts of locomotive. Any deviation from signed technical specifications will be

reflected to client and meets the clients written acceptance prior to

implementation.

The attached drawings and photos are only for reference, and QS may make

proper adjustments under the condition that will not affect the performance of the

locomotive. The manufacturing drawings according to client requirement are

subject to meet the client approval in design liaison phase.

For definition terms and conditions of design liaison phase ref to the contract.

CSR QISHUYAN LOCOMOTIVE CO., LTD.


BASIC PRINCIPLE

General The offered freight locomotive will fully meet with this technical specification. The

performance and commitment shall also fully meet with the relevant clauses of the

contract to be mutually agreed by the supplier and the customer. In order to meet

with the requirements from the Iranian customer, QS constitutes the following

basic principles and the norms.

Basic Principle The life cycle of the locomotive shall be 30 years. The design of the general layout,

subsystem and major parts and components of the locomotive shall be optimized.

While the reliability and easy maintenance shall be guaranteed, and advancement

of the technology and economical in use of the locomotive shall also be ensured.

To enable the client to operate and maintain the locomotives efficiently,

convenient technical documents including operating manuals, troubleshooting

manuals, maintenance instructions (for scheduled and corrective maintenance),

wiring diagrams and condition monitoring leaflets will be provided in English.


1 GENERAL DESCRIPTION

1.1 Overview

This design of Iran freight locomotive has been worked out based on DF8B diesel

locomotive developed by CSR Qishuyan Locomotive Co., Ltd. (hereinafter refer to

as QS) and taking into the consideration of RAI.

Model DF8B diesel locomotive is the freight transport locomotive specially used

on Chinese mainline, which was researched & developed successfully in 1997,

Over 1000 units have been produced by now. Among those, 200 units are put into

use in the Lanzhou- Xingjiang railway of Chinese desert region. In the year of

2006, 12 units of DF8B (DF8BVEN also called CKD4C type with 25 ton axle load)

diesel locomotives were successfully exported to Venezuela. The facts proved

that this type of locomotive has high ability and good economic performance.

The followings are the details of the major components of DF8BI diesel

locomotive. We are confident that the over all performance of the locomotive to be

supplied by our company shall be of the advanced international level.

1) Diesel Engine

16V280ZJA diesel engine with the advanced fuel injection system will be adopted,

which was designed and manufactured by QS .The first diesel engine was

successfully applied to locomotive in 1984and up to now more than 2000 diesel engine locomotives are equipped with this type of engine in China. Including the

DF8 locomotive, DF8B locomotive, DF11 locomotive, DF11G locomotive and

DF11Z locomotive, etc. Even the locomotives exported to Venezuela that

manufactured by our company are also equipped with the 16V280ZJA type

engine. This type of engine has the advantages of low fuel consumption, boost

economical efficiency, high reliability and good maintainability.


2) Alternator

The alternator will be matched with the engine of the locomotive. The

advantageous feature of the alternator is three phases with salient poles and

single shaft extensions.

The main alternator will be manufactured by a Chinese well-known company.

In the respect of manufacturing engineering, most of the major equipments with

advanced technology have been introduced from world famous companies to

ensure the quality of alternator.

3) Traction Motor

The traction motor with high traction effort will be chosen for the locomotive

The traction motor will be manufactured by a Chinese well-known company.

In the respect of manufacturing engineering, most of the major equipments with

advanced technology have been introduced from world famous companies to

ensure the quality of motors.

4) Electrical Control System

AC - DC transmission shall be adopted

On board microcomputer control system with 32 bits microcomputer system,

which is most advanced and successfully used in Chinese locomotive based on

MCU68332 CPU will be applied.

The main electrical elements will be supplied by a Chinese joint venture with

German SCHALTBAU.

5) Car Body

Load bearing structure with inside corridor is to be adopted for the locomotive.


Automatic coupler is compatible with profiles as defined in UIC. The couplers

contour will be same as Iran locomotives coupler.

The car body strength comply with UIC standard.

6) Bogie

Integrated fabricated bogie frame, traction motor nose suspended with roller

bearing provided by Japanese KOYO Company, vertical damper of primary

suspension and lateral damper of secondary suspension provided by German

SACHS Company, and solid wheel will be adopted for equipment of the bogie.

The bogie has both good dynamic performance and high reliability. Bogie frame

strength shall meet UIC 615-4

7) Brake System

JZ-7 brake system will be adopted from China. Buyer reservses the right to

choose other international braking system(such as Knorr, subwebco, etc )

Stainless air pipe will be chosen for the air brake system of the locomotive.

8). Casting Articles The cast articles in the locomotive shall be manufactured in accordance with AAR

standard.

9). Welding Procedure The welding procedure of the locomotive shall be performed in accordance with

DIN-6700 standard.

1.2 General layout


Gen

eral

layo

ut

1ai

r dry

er

2au

xilia

ry c

onve

rter ;

3

cool

ing

fan

4fa

n m

otor

5ra

diat

or

6ex

pans

ion

tank

7

exha

ust

pipe

8

dies

el e

ngin

e9

mai

n al

tern

ator

10

dyna

mic

bra

ke d

evic

e11

m

ain

silic

on r

ectif

ier

12

air

cond

ition

er

13

coup

ler

14--t

ract

ion

mot

or

15

front

blo

wer

(1)

16

exci

tatio

n m

otor

17

mai

n re

serv

oir

18

fuel

tank

19

batte

ry2

0st

art o

il pu

mp

21

heat

er e

xcha

nger2

2oi

l filt

er2

3re

ar b

low

er2

4bo

gie

25

hand

bra

ke d

evic

e26

sa

nd b

ox2

7ai

r com

pres

sor 2

8au

xilia

ry g

ener

ator

; 29

rear

tran

smis

sion

gea

r bo

x 30

ai

r filt

er3

1st

art m

otor3

2fro

nt tr

ansm

issi

on g

ear b

ox3

3fro

nt b

low

er(2

)34

lo

w v

olta

ge c

abin

et

35

high

vol

tage

cab

inet

36

driv

er c

hair;

37

cons

ole


1.3 Location of Apparatus

Load bearing structure with inside corridor is to be adopted for the car body. The

locomotive consists of top part and bottom part. The top part is the car body

including two (2) driving cabs, one (1) electrical apparatus room, one (1) power

room, one (1) cooling room and one (1) auxiliary room. The roofs of these room

and all kinds of equipments are fixed on the locomotive. Bottom part includes the

two (2) bogies, one (1) fuel tank, two (2) main air reservoirs and cowcatchers.

1.3.1 Driver cab

The design of driver cab will in according to the UIC651 standard. Such as the

measurement, control concepts, amenities and ergonomics. The drawings should

be approved by RAIs experts in design liaison phase.

The arrangement and the decoration of the cab and the cab is almost identical. The main differences lie in two point, A middle door is designed in

partition wall behind the cabfor electric component maintenance; Hand brake device that be only assembled in the middle of partition wall in cab . Both of two cabs are provided with completely identical manipulate function. There are front

windows and side windows in both cabs.

The ceiling installed on the top of the cab divides the inner of the cab into two

parts, the upper part and the under part. The upper part is the space where the fan

exchanges air, and the under part is the working room. The cab fans are installed

on the left and the right of ceiling; top board door and the outlet of air condition are

installed on the middle of the ceiling. Fluorescent lamps are on the both side.

There is a stationary type driver seat of which the height and the position of fore

and after could be adjusted according to drivers requirement. Meanwhile there is

an unfixed type seat for assistant driver or crew of which other function is similar


with former.

Ergonomic features are fully considered in designing of the operating console.

The layout of the control apparatus is right side operation type and single operator

type. All of the control apparatus and information aero are reasonable for easy to

operate and convenient for watching in the driver side.

Air conditioner is installed on the ceiling board at the end of cab I and cab II.

1.3.2 Electrical apparatus room

In the left of the room there sequentially locates the high voltage electric cabinet

and the main silicon rectifier cabinet. Under the main silicon rectifier is the blower

that cooling the main silicon rectifier cabinet and the main alternator. A fire

extinguish lie in left side of rear partition wall.

In the right of the room there installs the low voltage electric cabinet (including the

computer control cabinet) and front bogie traction motor blower.

The upside of the electric room is the air passage of front blower.

1.3.3 Power room

There are the diesel generating set, the front transmission gearbox, the starting

generator and excitation motor located in the power room.

Two sets of fuel pump and motor assembly; fuel filter is installed on the left of the

diesel and generator set. At both sides of diesel engine, air filter, car-body

ventilator and oil filling port are equipped respectively. Fire extinguisher is

mounted on the front end of left air filter and the rear end of right air filter.

At the upper part of the front partition wall there is dynamic braking equipment

across electric and power room, A contain box for magnet valve and sensor of brake system is at the contrary side.

At the upper part of the rear partition wallthere is a expansion tank for cooling water system, just below the tank there is a contain box for gauge and instrument.


1.3.4 Cooling room

V type cooling device, on which 54 sets of copper radiators with double

flowing-way are fixed, is installed at the upper part of the room. In the room two

sets of AC motors and cooling fan are installed.

In the middle of its under part, there is a blower for the rear bogie. Oil heat

exchanger is on its left side. And oil filter are on its right side.

The air compressor sets, auxiliary generator, gearbox are on the floor.

1.3.5 Auxiliary room

From the top down of partition wall there are air dryer, brake valve and relevant

appurtenance in sequence.

The ladder going to roof of the locomotive is on the left of rear partition wall.

The auxiliary AC converter will be fixed on the partition wall of auxiliary room.

Other parts including the magnet valve box-, electrical magnet valve for dead man system will also be located in the auxiliary room.

1.3.6 Roof

The roof of electric room, power room and auxiliary room can be removed, which

equips with the lifting lug and can use the crane to lift the roof easily when the

parts of these room need to be repair or maintenance on the ground


This blank page is left here intentionally for any amendment


2 GENERAL DATA

2.1 Key technical characteristic

Table 1

No. Content

1 Both single-unit operation and double-heading operation are providing

with the locomotive

2 The main transmission of the locomotive adopts AC-DC electric

transmission system. The 3-phase AC current generated by the main

alternator after rectified by silicon rectifier device is changed to DC

current, and then the DC current is delivered to six parallel-connected

traction motors.

3 Double set microcomputer control systems are providing, in which one

set is for backup.

4 Magnetic field weakening for DC traction motor adopts single stage

method in the main electric control circuit.

5 The control circuit and light circuit of locomotive adopt 110V DC.

6 Axial-flow cooling fan adopt AC motor driven and the rotate speed is

governed by temperature of cooling water automatically.

7 The structure of car-body is of truss type with sidewall bearing the load

with double cab.

8 Locomotive equip with two set bogies with stiff rubber side bearing,

axle box positioned by pull rod and two-stage suspension. The

suspension mode of traction motor adopts nose-suspension with rolling

bearing. The wheel is mono-block type. Traction effort and brake effort

are transmitted by low position draw bar.

9 The brake system is JZ-7 model air brake from China

10 The AC auxiliary system mainly including the auxiliary generator, the

auxiliary converter and the AC motors for two cooling fans and two

traction motor blowers.


2.2 Key technical data

Purpose: The locomotive is designed for main line Freight

transportation and it also can be used Under the

electrified lines by complying with EN50121

standard

Operation region: Iran

Operation condition

The climate condition has been taken into account during designing procedure,

including temperature, humidity, rainfall amount etc.

Table 2 Operation condition figure

No. Items Content 1 Max. Temperature in hottest season 50 2 Min. temperature in coldest season -30 3 Relative humidity 100% 4 Max. Latitude of rail line 2400m

5 Worst condition Altitude=1400m & Temp=45 Desert condition


2.3 Key basic technical data of locomotive

Table 3 Key basic technical data

No. Items Description

1 Gauge 1435mm

2 Clearance UIC 506-GC

3 Transmission Mode AC-DC electric transmission

4 Axle arrangement C0-C0

5 Nominal Wheel Diameter 1050mm

6 Axle Load (230.69) t

7 Calculated Gross Weight 138 t (EN15528 under IEC61133 condition)

8 Max. Service Power of

Engine

3680kW (Under the UIC condition, the amendment

mode of engine power adopts ISO3046-1

formulation, which rely on concrete figure of

circumstance temperature and latitude to carry out

amendment.)

3250 kW(under the worst site condition )

9 Traction power 3390kW (under UIC)

2950kW(under the worst site condition )

Speed of Locomotive (Calculated wheel diameter is half abrasion

condition, namely 1013 mm.)

a) Max. Test Speed 110km/h (comply with UIC518 standard)

b) Max. Service Speed 100km/h 10

c) Continuous Speed 28.2km/h (Continuous current limit)

30 km/h (Adhesion limit)

Traction Effort on Wheel 11

a) Max. Starting Effort 520 kNTraction motor capacity

440kNAdhesion capacity


b) Continuous Effort 369kNTraction motor capacity

347kNAdhesion capacity

12 Min. Negotiation Curve

Radius 80m(single locomotive with speed below 5km/h)

Wheelbase

a) Wheelbase 1800mm

b) Bogie Wheelbase 3600mm 13

c) Total Wheelbase of

Locomotive 15900mm

Locomotive Dimensions

a) Length Between

Coupler Pulling Faces 22220mm

b) Width 3025mm (Total width including handrail, mirror etc)

2950mm(Width of car-body)

14

c) Height 4650mm

15 Capacity of fuel tank 9000L

16 Capacity of engine oil 1200L

17 Capacity of engine

cooling water 1200L

18 Capacity of sand 800kg

19 Centerline Height of

Coupler above rail 1040+5 0 mm

20 Centerline Height of

buffer above rail 1060+5 0 mm

21 Coupler Willison type U profile acc to LAF 1858

22 Buffer Suitable buffer match with the coupler.


2.4 Technical data of Key parts of locomotive

2.4.1Engine

Table 4


1 Model 16V280ZJA

2 Style Four-stroke, turbocharged, inter-cooled, direct fuel injection combustion chamber

3 Cylinder number and arrangement

16 cylinders, 50 V array

4 Max. Service power

3680kW (Under the UIC condition, the amendment mode of engine power adopts ISO3046-1 formulation, which rely on concrete figure of circumstance temperature and latitude to carry out amendment.)

5 Bore diameter 280mm

6 Piston stroke 285mm

7 Rated speed 1000r/min

8 Lowest idling speed: 400r/min

9 Direction of rotation (facing output end)

Clockwise

10 Starting mode Electric motor starting

11 Diesel engine overall dimension (lengthwidthheight)

4867.5mm1725mm2895mm

12 BSFC 205+3% g/kWh (under UIC condition)

13 Oil consumption 2.04 g/kWh (under UIC condition)

14 Effective pressure 1.65MPa


15 Firing pressure 13.72MPa

2.4.2Bogies

Table 5


1 Main characteristic

The bogie consists of bogie frame, axle box, wheel set, side bearing system, drawbar, foundation brake rigging, sand box, traction motor and suspension assembly, lubricating device for wheel rim, stone wiper and other appurtenance etc.

2 Main technical data

a) Axle arrangement C0-C0

b) Suspension mode of traction motor

The suspension mode of traction motor adopts nose-suspension with rolling bearing

c) Wheelbase 21800 mm d) Gear ratio 77:17

e) Max. Service speed 100km/h 3 Derailing factor 1.0 (meet with ERRT 55PR8)

4 Derailing factor of wheel load 0.6

5 Overturning factor 0.8 6 Foundation brake device Brake unit

7 Hand brake device Parking locomotive is available at 25 grade rail with the condition of good climate and rail surface.

2.4.3Synchronization generator

Table 6

No. Items Description 1 Model JF204D series 2 Rated capacity 3700kVA 3 Power factor 0.95 4 Rated voltage 507 V / 770 V 5 Rated current 4215 A / 2775 A 6 Max. Current 5610 A


7 Rated speed 1000 r/min 8 Excitation mode Separate excitation

9 Cooling mode Forced ventilation (Ventilation quantity is 270 m3/min)

10 Rated efficiency 96.5 11 Insulation class H/H

2.4.4Traction motor

Table 7

No. Items Description 1 Model ZD109E 2 Rated power 630 kW 3 Rated voltage 755 V/1000 V 4 Rated current 900A/680 A 5 Max. Current 1260 A 6 Rated rotate speed 855 r/min 7 Max. Rotate speed 2465 r/min 8 Excitation mode Series excitation 9 Operating mode Continue

10 Magnetic field weakening Single stage, Max. weakening ratio is 48 11 Rated efficiency 92.7%

12 Ventilation mode Forced ventilation (Ventilation quantity is 110 m3/min)

13 Max. Torque 10952 Nm 14 Continue torque: 7055.5 Nm 15 Insulation class H/H 16 Weight 2950kg

2.4.5Starting generator

Table 8


1 Model ZQF-412

2 Rated power 80 kW

3 Rated voltage 110 V


4 Rated current 728 A

5 Rated speed 2728 r/min /1051 r/min

6 Excitation mode Separate excitation (generator condition);

Series excitation (motor condition)

7 Excitation capacity

(Generator condition) Excitation voltage105 V, Excitation current8 A

8 Ventilation mode Self-ventilation

9 Start torque: 3296 N.m(battery voltage 96V,start current is

2100A)

10 Firing torque: 1684 N.m(diesel engine reach 273 r/min)

11 Working mode Continuous working

12 Insulation class F/H

13 Weight 850kg

2.4.6Main silicon rectifier

Table 9

No. Items Description 1 Model TGZ30 series 2 Rated DC output voltage 1000 V 3 Rated DC output current 5600 A 4 Max. DC output current 8000 A15min

5 Rectifier component type and quantities

ZPX3000-30 type, 12 pieces

6 Rectifier mode Threephrase bridge type rectifier circuit

2.4.7 Auxiliary generator


Table 10


1 Model JF417SX1

2 Rated capacity 400kVA

3 Rated frequency 87.6HZ

4 Rated voltage 480V

5 Rated current 480A

6 Rated rotate speed 2680r/min

7 Number of phases 3

8 Rated power factor 0.85

9 Stator connection Y-Y

10 Excitation method: Brush-less, separate-excitation

11 Excitation voltage 110V

12 Rated excitation current 5A

13 Insulation class H/H

14 Cooling method: Self-ventilation

15 Weight 1100kg

2.4.8 Auxiliary Converter

Table 11

No. Items Description 1 Model OCPI4I 2 Rated capacity 140kVA 3 Rated voltage 480V 4 Rated current 170A 5 Cooling method Force air cooling 6 Weight 350kg


2.4.9Blower motor

Table1 2

No. Items Description 1 Model: JD800 2 Quantities: 2 3 Number of poles: 4 4 Rated power: 45 kW 5 Rated voltage 480V AC 6 Rated current: 66A 7 Rated rotation speed: 2594rpm 8 Rated frequency: 87.6Hz 9 Rated efficiency: 0.929 10 Rated power factor: 0.897 11 Insulation class H/H

2.4.10Cooling fan motor

Table13

No. Items Description 1 Model JD801 2 Quantities 2 3 Rated power 82kW 4 Rated voltage 480V AC 5 Rated current 123A 6 Rated rotation speed 1295rpm 7 Rated frequency 87.6Hz 8 Rated efficiency 0.945 9 Rated power factor: 0.85

10 Insulation class F 11 Cooling method: Self-ventilation

2.4.11 Compressor motor

Table 14

No. Items Description 1 Model ZTP-180CG 2 Rated power 22kW 3 Rated voltage DC110V


4 Rated current 225 A 5 Rated rotate speed 3000 r/min 6 Insulation class F/F 7 Protection method IP22 8 Excitation method Series excitation 9 Cranking method Direct

10 Cooling method Self ventilation 11 Working mode Continuous( S1)

2.4.12Battery

Table 15


1 Model GNC210 super-high ratio Cadmium-Nickel alkaline battery

2 Capacity 210 Ah discharging for 5 hours 3 Rated voltage 93.6 V

2.4.13On Board Microcomputer

Table 16

No. Items Description 1 Style Plug in unit 2 CPU MC68332, 32 bit 3 Power supply DC 110V 4 Display mode LCD screen

2.4.14 Dynamic brake device

Table17


Dynamic brake device 1 Model TZZ11B(I) 2 Main characteristic Horizontal structure, forced-ventilation 3 Rated current 730 A 4 Rated current 800 V 5 Self-load power 21750 kW


6 Max. Voltage 960 V 7 Operation temperature 640

Motor of Dynamic braking device 1 Model ZTP-63B 2 Quantities 2 3 Rated power 30KW 4 Rated voltage 260 V 5 Rated current 136 A 6 Rated speed 3500 r/min 7 Max. speed 4000 r/min 8 Insulation class F

Blower of Dynamic braking device: 1 Model: XAFJ-8B 2 Type Axial flow 3 Quantities 2 4 Driven mode D C motor 5 Rated speed 3500r/min 6 Air flow 633m3/min

2.4.15Air conditioner

Table 18

No. Items Description 1 Model JK8.0L/BPH-A01

2 Circumstance temperature

-30+50

3 Power supply 110VDC 4 Refrigerant R134A 5 Refrigerating capacity 2000W-8000W

6 Max. power for refrigerate

4,000W

7 Max. current for refrigerate

40A

8 Starting current 1A 9 Relative humidity: 953% (40)

10 Reliability: MTBF3000h


2.4.16 Electric Heater

Table 19

No. Items Description Heaters located on side wall in driver cab

1 Model QSD4 2 Quantity 2 3 Power 1000W 4 Voltage DC110

Heater located on divided wall in driver cab 1 Model : QSD5 2 Quantity 2 3 Power 1500W 4 Voltage DC110

Heater located under console for feet 1 Model SDF-500 2 Quantity 2 3 Power 500W 4 Voltage DC110

2.4.17Cooling equipment

Table 20


Radiator

1 Type Copper radiators with double flowing-way Cooling fan

1 Type Axial flow 2 Quantities 2 3 Diameter 1,600 mm 4 Driven mode AC motor 5 Air flow: 2160m3/min


2.4.18 Main alternator Blower

Table 21

No. Items Description 1 Type Centrifugal 2 Quantities 1 3 Rated rotation speed 2960rpm 4 Air flow 330m3/min 5 Air pressure 5000kPa

2.4.19 Traction motor Blower

Table 22

No. Items Description 1 Type Centrifugal 2 Quantities 2 3 Rated rotation speed 2594rpm 4 Air flow 330m3/min 5 Air pressure 5000kPa

2.4.20 Brake system

Table 23


Pneumatic Brake

1 Type: JZ-7

Air Compressor set

1 Model TSA-230D 2 Quantity: 2

3 Displacement 2.4 m3/min

4 Input air pressure 100 kPa

5 Outlet pressure of

compressed air: 900 kPa

6 Rated speed 3000r/min


7 Cooling method: Air

Air dryer 1 Model: SJKGC1 2 Quantity 1 3 Dispose capacity 5m3/min 4 Relative humidity (RH) 15%

5 Ambient temperature limit

-40+50

6 Operating cycle 90(120)15%S 7 Time controller type DDS digital electric controller 8 Control voltage DC 11010V 9 Dryer unit weight 148kg


3 PERFORMANCE

3.1 Horsepower

Maximum service power of the locomotive is 3680kW (5000hp).

3680kW is the diesel engine output power obtained under UIC condition defined

as below (for UIC Rated Power).

Intake air temperature: 25 C Altitude above sea level 100 m Barometric pressure 1000 mbar Intake air depression 25 mbar Exhaust back pressure 30 mbar If ambient temperature or altitude is above the limit defined by the relevant

standard, diesel engine output will be derated to normal level the power

modification of engine with the change of temperature is as follows:

UintkW The power of engine will not be needed to be modified, when the elevation is


below 2000m, and the power modification of engine shall be modified by 2% when

the elevation is increased by every 200m if the altitude is above 2000m.

3.2 Traction Performance

When the locomotive is operating at full horsepower and power consumption of

the cooling fan is at two-third level, the maximum traction effort shall be 440kN,

the continuous traction effort shall be 347kn(adhesion limit), and the maximum

running speed at constant horsepower shall be 100km/h.

Note :Rolling resistance formula adopts the following:

Locomotive resistance formula: o=2.40+0.0022V+0.000391V2 (N/kN)

Rolling stock resistance formula

o=0.92+0.0048V+0.000125V2 (N/kN) The V is speed of train with km/h

Traction performance curve of the locomotive, please see attached drawing of

technical specification.

3.3 Brake Performance

The emergency brake distance shall not be greater than 800m with air brake

system alone, for single locomotive running on straight and flat track at 100km/h

prior to brake application. This will apply on rail that is dry or wet (water) and clear

of ice, rust and oil.

Dynamic brake performance curve, please see attached drawing of technical

specification.


NOTE:

The traction and dynamic brake performance is calculated based on theoretic. If

practice operation condition has deviation with boundary condition of theoretic,

such as bad climate and rail situation, the real operation performance of

locomotive might be deviated theoretic figure accordingly

The locomotive has the protections for slip and sliding. If its lack of adhesion

during starting, braking process or running on the way, the anti-slip or anti-sliding

measurement will be put into automatically by microcomputer system, such as

alarm and automatic sanding or decrease the dynamic brake force.


3.4 Hauling Capacity of Loco Against Different Gradients


4 CAR BODY

4.1 Overview

The car body of the locomotive supplied to Iranian customer is a load-bearing

structure car body, the steel structure of car body is consisted of the under-frame,

the left and right side walls, the roofs, the partitions and two driver cab by welding.

The strength of car body complies with UIC 566.

4.2 Under-frame

The under-frame is weld that consists of the front and rear draw beams, the

transoms, the side-bearing beams, the beams used to support diesel engine, the

side beams and the cover and so on.

The couplers and draft gears are mounted in each draw beam located at end of

the under-frame. Lifting eyes are provided at two sides of the under-frame near

the side bearing beams and the rescue lifting eyes for rerailing are designed at

the two side of the under-frame near the draw beam.

4.3 Sidewall

The truss-frame structure is utilized for sidewalls to satisfy the load bearing

requirements, which needs sidewall to bear huge flexural torque in the middle of

car-body and avoid permanent distortion to happen during the course of

locomotive lifting operation as well as performing succor task in case of

locomotive derail.

4.4 Driver Cab

There are two doors respectively located on the side of the driver cab for the


driver and his assistant in and out. Close attention is given to the ergonomic

concerned. The design of the structure and the arrangement in the cab is featured

with ease of maintenance and operating.

The front window can offer a good view for driver, and side window that can move

are located the both side of side walls, both the front window and side window are

equipped with the window shade that can adjust its position to prevent the sunlight

beat the drivers eyes.

The design of driving cab complies with UIC651 standard.

4.5 Electric Apparatus room

The electric apparatus room is located behind the driver cab I. It is used to install

all kinds of electric apparatus.

With concerns to supplying excellent performance in maintenance accessibility,

the arrangement and assembly methods of electric apparatus would be fully taken

into account. To maintain electric apparatus work at suitable operating

temperature range, ventilation structure would be optimized based on QS

longstanding experience in this aspect. Meanwhile, rainproof and damp proof

measures would be applied to create a favorable work environment for electric

apparatus and keep them away from damage by harmful climatic conditions

4.6 Power room

The power room is located between the electric apparatus room and the cooling

room. At both sidewalls there is a ventilator to drain the hot air out of the power

room to reduce the air temperature in it.

The power room will be the positive pressure in it to prevent the dust from

entering.


4.7 Cooling room

The cooling device is mounted on the top of it. Shutters are installed at each side

of the sidewall, Its open or close is determined according to the temperature of

the cooling water.

In the room, anti sand measure will be taken. So that to supply the clean air to the

blower for the traction motors in the rear bogie.

4.8 Auxiliary room

The auxiliary room will be placed in between the driver cab II and cooling room.

4.9 Fuel Tank

The fuel tank will be made of steel plate with internal baffles that can reduce the

spill and prevent the overflow.

One fuel filler with internal basket strainer and cap are arranged, which are

located on each side of the fuel tank.

Both sides of the tank will also be equipped with fuel gauge to display the fuel

level.

And a manhole cover at the bottom of tank can be used to conveniently inspect

and clean the inside of fuel tank.


4.10 Waste Retention Tank

The waste retention tanks are located under both the front part and the rear part

of the engine-generator set. A pipe with valve of each retention tank can be used

to drain the wastewater and oil out of the car body according to the maintenance

schedule to reduce the pollution of the rail.

4.11 Roof access ladder

A ladder will be mounted in the auxiliary room for driver and assistant to get on &

off the locomotive top.


4.12 Handrails and steps

According to UIC 651 standard, the handrail and steps will provided for the drivers

and other related people to get on and get off the locomotive.

4.13 Doors & Door Stops

A locker that used to lock the locomotive is installed in very doors. Doorstops of the doors in the cab are arranged for protection of the finishing and

the decals of the surface of the car body, from damages when the doors are

opened.

4.14 Lifting/Jacking

The lifting/jacking/droptables positions are located along the two sides of the car

body, four support seats will be provided near the draw bar seat for support the

locomotive, four lifting holes are near the support seats. If it necessary, the holes

can be used to lift the locomotive via the lifting device, such as shipping by sea.

Another four holes (succor holes) will also be provided near the driving cab. When

the locomotive derail or need to rescue, these holes can be used.

The two bogies can be lift with the locomotive after they connect with the car body.

And its possible to lift one head with the bogie when accident or derail.

Two rerailment tools will be provided with the locomotive.

4.15 Roof

The removable roof is fixed on the top of car body, which equips the lifting lug can

use the crane to lift the roof easily.


4.16 Side shutter

The side shutter consists of the aluminum frame, a-alloy laminas set ,the

connecting lever and the handing on-off mechanism etc

The air cylinder automatically controls the shutters of cooling room.


4.17 Eaves

The eaves will install at both topside of car body, can drain the rainwater quickly

from the car body, and prevent the rainwater effectively entering into the inside of

locomotive.

4.18 Convenience of Maintenance

Convenience of maintenance has been fully considered during the design in a

way that, for normal routine maintenances of the ordinary components and parts,

no need for workers to go up on the roof of the locomotive. Similarly, efforts will

also be made to facilitate that even for the maintenance of major big sized

components going up on to the roof of the locomotive shall not be necessary, or at

least minimize the need of going on to the roof.

4.19 Coupler

The couplers type is Willison type U LAF1858 automatic coupler, not only can

connect the same type automatic coupler, but also can connect with the chain

coupler that used in Iran

4.20 Buffer

Four buffers will be supplied beside the couplers at end of the locomotive. The

model will be the same as the Iran current buffer or suitable one that be accepted

by RAI.


4.21 Major material of the car body

No. Name Material 1 Main structure of driving cab Q345B 2 Main structure of body frame Q345B 3 Cover plate of body frame Q235A 4 Main structure of side wall Q345B 5 Main structure of top frame Q235A


5 BOGIE

5.1 Overview

The freight locomotive has two three-axle bogies, and the axle arrangement is

C0-C0. There is a traction motor on each axle.

The bogie frame is of full-welding frame structure composed of two side beams


and four cross beams. The motor suspension gear is of nose suspension with

rolling bearing. The wheel adopts monoblock wheel. The resilient axle box pull rod

together with axle box spring positions the axle box. The secondary suspension

mechanism is of side bearing system. The draw bar is used to transmit the

traction or braking effort between the bogie and the car body. The foundation

brake rigging is of individual action-type unit brake, which acts unilaterally on each

wheel. Furthermore, there is a sand box and flange greaser on each end of the

frame.

5.2 Bogie construction

The bogie consists of bogie frame, axle box, wheel set, motor suspension gear,

secondary suspension mechanism, foundation brake rigging, draw bar and

accessories.

5.3 Bogie frame

The bogie frame is of fully welded frame structure with bracing plate for increasing

holistic rigidity and improving the stress status. The bogie frame consists of two


symmetrically arranged side beams, four cross beams and some seats for installing

the other accessories. The side beam is of frame structure welded with

high-performance steel plates. Side bearing seats and cross damper seats are

welded on the top surface of the side beams, side stop piece seats and vertical

damper seats of primary suspension mechanism on the side faces, axle box pull

rod seats and spring seats on the bottom surface and sand box seats and flange

greaser seats on each terminal. Pendulum link seats and brake rigging seats are

welded on the crossbeams.

Fram

e

1fr

ont e

nd b

eam

;2

side

bea

m;3

dam

per s

eat;4

cr

ank-

arm

seat

;5

cros

s bea

m;6

mot

or

hang

er;7

uppe

r pul

l rod

seat

;8

low

er p

ull r

od se

at;9

side

bea

ring

seat

;10

brak

e se

at;1

1re

ar

end

beam

.


5.4 Axle box

The axle box is composed of axle box pull rod, axle box body, axle box bearing,

Axle box spring and vertical damper of primary suspension mechanism, etc.

The axle box is positioned by resilient axle box pull rod together with independent

springs. The spring of the primary suspension mechanism consists of steel spring

in series with rubber pad. The axle box body is made from cast-steel. The vertical

damper of the primary suspension mechanism is fixed between the axle box and

the bogie frame. The damper is the product of SACHS.

Axle box 1lower axle box link;2box body;3damping pad;4spring seat;5outer spring;6inner spring;7spring cover;8upper axle box link;9dust guard ring;10rear cover;11box body lateral stop;12vertical damper;13gland;14end cover;15angle ring ;16rolling bearing;17space ring ;18rolling bearing;19outer cover.


5.5 Wheel set

The wheel set is composed of the left wheel, right wheel, the axle and driven gear,

etc. While the locomotive is running with high speed, the active force produced on

both the wheel and the rail due to the nonhomogeneous of the material, can be

reduced largely by the whole machining procedure, as a result, the dynamic

performance of the locomotive is improved effectively. The axle is made of the steel

JZ45 according to the UIC Standards and has been applied for a long time.

The physical dimensions of the left and right wheels are of the same. And the

wheels and the driven gear are fixed directly on the axle. The type of wheel tread

is in compliance with the UIC standards.

The mechanical performance and chemical composition of the wheel conform to

the UIC812, and the wheel rigidity complies with R8.

Wheel-set

1wheel;2driven gear;3axle;4plug bolt.


5.6 Motor suspension gear

The arrangement of the motors is of parallel layout. The motor suspension gear is

of nose suspension mode. One end of the motor is supported from axle with roller

bearing and nose suspension box, another supported from transom of bogie

frame with a pendulum link and rubber pad. The nose suspension box connects

the traction motor firmly by the wedge and the bolts.

Traction motor suspension (u-tube structure)

1dust guard ring3;2dust guard ring4;3driving bearing1TR483608SS;4big-end bolt;5u-tube;6small-end bolt;7driving bearing2TR483205SS;8adjusting shim1;9bearing seat;10dust guard ring1;11dust guard ring2;12adjusting shim2;13gear case assembly;14air ducts assembly;15suspension link assembly;


5.7 Gear and gear cover

The gears are made of low-carbon alloyed steel with excellent mechanical property.

The gear cover made of sheet steel is of non-load structure. It is divided into two

partsthe upper part and the bottom part by the plane formed by the axis of the traction motor and the axis of the axle.

5.8 Side bearing

Side bearing is the secondary suspension mechanism between the frame and car

body. The bearing carrier is the rubber suspension pad which has the good

performance and needs little maintaining work through which the vertical load,

moving load and transverse load of the car body are transferred to the bogie.

Rubber suspension pad is of a rather large displacement of each direction and

has a rather large restoring force and restoring moment. It consists of steel plates

and rubber sandwich bonded together by sulfurzing. Additionally, there are two

transverse dampers in the secondary suspension mechanism to attenuate the

transverse vibration.


5.9 Foundation brake rigging

The foundation brake rigging is wheel tread brake. There are six independent

brake units that can act independently and unilaterally on the wheel tread in each

bogie. Each unit brake is fixed to the brake rigging seat of the bogie by 4M16 bolts. There are two unit brakes acting on the same axle of one bogie that can be

connected to the hand brake device. The brake unit has such characteristics: high

efficiency, reliable performance, lightweight and small volume and little

maintenance etc. There are thousands of locomotives in China railway with this

brake unit.

Side bearing 1Metal-rubber sandwich block2lateral oil damper


Brake rigging schematic arrangement 1QB-7 brake unit; 2QB-7S brake unit


QB7S brake unit 1 brake shoe;2 inserted pin;3 brake shoe pin;4 brake shoe holder;5 brake shoe supporting;67nut;8guiding sleeve; 9case;1017adjusting spring;11force-pushing retainer ring;1251108 bearing;13adjusting nut;14lever;15adjusting nut sleeve;16guiding nut;18flat key;19guiding nut sleeve;20pressing ring;21resetting retainer ring;22clearance adjusting block;23end cover;24block sleeve;25screw rod;26pin shaft;27spring; 28screw cap;29pulling ring;30guiding ring;31rubber cup;32release spring;33 piston pushing pole;34 fitting;35 brake cylinder;36 pin;37 lock spring;38 51110bearing; 39washer;40pin shaft;41dustproof cap;42screw rod pin.


5.10 Draw gear

The draw bar is used to transmit the traction or break effort between the bogie and

the car body. Its advantage is that can effectively reduce the axle load transfer.

5.11 Flange greaser

The dry-type flange greasers are set on the end of the bogie to reduce the

wearing away of the rim. The type of flange greaser is the forth-bounced type. The

greasing block leans on the rim with the effect of the elastic force of the spring.

The dry-type lubricant film is formed when the wheel rotates and anti-attrition is

Draw Gear 1draw bar,2crank arm, 3connecting rod, 4dust plate, 5dust ring, 6separating sleeve, 7draw pin, 8grease cup, 9brace, 10bolt, 11gland, 12spherical plain bearing,13draw bar pin, 14nut, 15separating sleeve, 16cushion, 17connecting rod pin, 18crank arm pin


realized and achieved.

This kind of greaser is characterized by its simple structure; easy operation, low

cost and few failures, and which is widely used in all kinds of locomotives, such as

the locomotives that export to Venezuela. It can prolong the service life of the rim.

5.12 Damper

There are 4 side bearings fitted between each bogie and the car body to reduce the

vibration of every direction. The primary vertical damper is fixed between frame and

the end axle box to absorb the vertical impact and vibration between the rail and

the wheel, i.e., 4 vertical dampers per bogie. The lateral damper is fixed between

the car body and the bogie frame to absorb the lateral vibration between the bogie

frame and the car body. The dampers are imported from SACHS Company in

Germany with excellent performance.


5.13 Accessories

Side stop piece of bogie is set in the middle of the bogie. Safety bracket is set on

the suspender seat of the transom of bogie frame. There are four sand boxes and

four sand tube installation interfaces at each of the bogie frame.

There are two lifting interfaces on both sides of the bogie frame so that the

connection between the bogie and car body is realized while lifted.


6 AIR SYSTEM AND BRAKE

6.1 Overview

The air system is composed of air supply system, air brake system, sanding

system, air control system, horn and windshield wiper system, etc.

6.2 Air Supply System

The air supply system consists of air compressor set, compressor governor, check valve, air dryer, main air reservoir and high-pressure safe valve, etc. Two spiral

lobe compressors with the capacity to deliver 2.4m3/min (each) of compressed air

are driven by the DC motors. The compressor governor controls the air

compressor to start or stop to keep the pressure of the main reservoir in between

750-900kPa. The air dryer is equipped between the air compressor and the main

air reservoir to get rid of the oil, water and dust, etc. in the compressed air, in

order to ensure the reliability of the brake system.


6.2.1Air Compressor

The screw type, air cooled air

compressor will be provided.

They are driven by DC motor

directly. Its rated displacement

is 2.4m3/min.

A safety valve is provided to

protect the compressor from

overpressure. Also a pressure

switch is provided before the first main reservoir to control the compressor to start

or stop. The compressor starts to work when the main reservoir pressure is lower

than 75020kPa, Stop working when the main reservoir pressure is higher than 90020kPa.

6.2.2 Air Dryer

Twin tower, regenerated style air dryer

will be adopted

An oil fine filter will be provided after

air dryer to prevent other additives

from entering the main reservoir.

6.2.3 Main Reservoir

Two main reservoirs, installed under

the carbody will be provided. Both

have the capacity of 625L. A drainage cock is provided on the main reservoir. And

the cock can be opened to drain the accumulated waterbecause air dryer is provided, general speaking, there will not be any accumulated water draining from

the main reservoir, if any ,the air dryer should be checked for normal use.


Two safety valves will be provided on the branch pipe of the main reservoir. Its

purpose is to prevent dangerous overpressure of the main reservoirs when the

pressure adjuster works abnormally. That is to say the safety valve will open when

the main reservoir pressure is (95020)kPaand a whistle from the safety valve will warn the driver. The main reservoir pressure will not keep increasing although

the compressors are running. The safety valve should be lead sealing after

adjustment under air source over 950kPa.

6.3 Air Brake System

The diesel locomotive is equipped with the Type JZ-7 Automatic Air Brake that

has good brake performance and high reliability. It has been used in all the diesel

locomotives in China for over 30 years, and the quantity is over 10,000 units.The

performance of JZ-7 air brake system is similar to 26-L air brake system that

widely used in Iranian Railway.

JZ-7 type air brake system is mainly composed of automatic brake valve,

independent brake valve; relay valve, distribution valve, action valve and

accessories concerned. The application of automatic brake valve can control the

braking, relief, and pressure holding of train, and the application of independent

brake valve can control the braking, relief and pressure holding of single

locomotive.

The automatic brake valve has seven application positions, namely over-charging

position, operation position, minimum release-pressure position (normally used

braking area), maximum release -pressure position, over- release pressure

position, handle taking-out position, and emergency braking position.

Independent brake valve has three application positions, namely independent

relief position, operation position, and full brake position.


Main Parameters

Automatic brake valve 1) Rated pressure inside the brake tube: Freight service: 500kPa;

2) The brake tube can obtain the over-charging pressure of 3040kPA when the handle of automatic brake valve is located at over-relief position. The

over-charging pressure will be automatically relieved within 150180s when the handle is moved to the operation position.

3) Normally-used brake

The train shall produce braking application when the minimum relief volume of

brake tube is 4555kPa. The maximum relief volume of brake tube when the whole train is under maximum

brake force: The relief volume is 140kPa when the rated pressure of brake tube is


500kPa.

The times are 58s when the brake tube is reduced from the rated pressure of 500kPa to pressure of 140kPa.

The time is 69s when the brake cylinder of locomotive is increased from the maximum pressure. The highest pressure of brake cylinder is 340380kPa when the rated pressure of brake tube is 500kPa.

4) Relief after normally used brake

After the normally-used brake, the train will be relieved when the handle is moved

to the operation position, and the time is 59s when the pressure of brake cylinder of locomotive is reduced from the highest value to the pressure of 35kPa.

5) Emergency brake

The time the pressure of brake tube is discharged to 0 under emergency brake

status:


Manual sanding: sanding at any time according to requirement to improve the adhesion of the train-set while starting in order to avoid wheel slipping.

Automatic sanding at the time of emergency braking is to improve the adhesion of the locomotive while braking in order to avoid wheel slipping.

Automatic sanding at wheel sliding is to improve the adhesion of the train-set to avoid wheel slipping.

6.5 Air horn system

The air horn system mainly includes the buttons, two magnet valves, two althorns

and two sackbuts. The four air horns will resound at the same time when the

driver trample the pedal switch under the console or push the manual button on

the console.

Low pitch horn or a pneumatically operated bell will be provided for shunting yards

and depots.


6.6 Windshield wiper system

A set of single brush-holder stud electric power driven windshield wiper is installed

on each windshield of the two cabs. Windshield wiper is composed of motor,

windshield wiper assembly, brush assembly, scrubber, controlling switch.

The motor is DC magneto electric machine. It consists of stator, rotor, front & rear

end cover and reduction gearbox.

Its driving parts of are of Windshield wiper unit assembly crank and rocker

mechanism.

Brush unit assembly mainly consists of brush-holder stud, arms.

The electric washer is composed of one washing solution tank, two washing

solution pump, hoses and nozzles. The cut-in or cut-out of the electric scrubber is

controlled by the special control button on the electric control switching. Electric

control switching has 3 positions: 0- park and resetting, 1-low speed, 2-high

speed.


6.7 Control Air System

The control air system which is mainly composed of the air reservoir for controlling

equipment and the pressure regulating valve is provided to supply pressure air to

the shuttle turning on structure and the to the electro-pneumatic valve in the

electric system.

6.8 Hand Brake System

The hand brake system that uses human power to create brake effort will apply

brake force to the locomotive stopped on the railway to prevent it from moving.

One set of hand brake system is provided on the locomotive. It mainly includes

the crank, block and tackle, gear, gearbox, steel wire rope and rail etc. Draw the

crank out and turn the crank clockwise to strain the steel wire ropethe rail will be strained after changing force direction by block and tacklethen the shifting fork assembly will be shifted by staining the steel wire rope at two side and shift the

lever of the brake unit to transfer force to lever to apply brake. The locomotive

brake will be released when turn the crank anti-clockwise.


7 DIESEL ENGINE

7.1 Overview

Locomotive adopts 16V280ZJA type diesel engine.

The engine is one of the series products made by QS and which is a kind of 280

series products made in QS.16 cylinders are arranged V type in the engine block,

and the engine has two turbochargers and two intercoolers.

The direct fuel injection system is used in 16V280ZJA diesel engine. There are

several safeguards to protect engine-running safety, such as over speed

protection, oil pressure low protection, barring over device interlock, crankcase

pressure protection.


16V

280Z

JA E

ngin

e co

nfig

urat

ion


16V280ZJA Engine cross-section


7.2 Lubricating oil System

For the 280-diesel engine, adopt pressure lubrications mainly with some splash

lubrications. This lubricating oil system with the oil pan has functions in lubricating,

heat transfer, cleaning, airproofing and buffering. It consists of oil pan, oil pump,

centrifugal oil filter, Turbo Oil Filter, regulator valve, relief valve, oil piping etc..

Sketch Map of Oil System


7.3 Fuel system

The fuel was injected to the cylinder in the certain time and certain quantity mix

with fresh air and combust in the cylinder. The diesel engine fuel system is made

up of fuel pipe, adjusting pressure valve, the fine filter, pump, injector, high

pressure line, fuel drain pipe and air vent pipe etc, and with the fuel supplying

pump, fuel tank, the first fuel filter, check valve and safe valve in the locomotive

compose of the whole fuel system together

Fuel system


7.4 Injector

Injector belongs to closed, multi hole, non-cooling, low inertia type with short U

type nozzle. It makes up of nozzle holder body, in-line junction, pressure

regulation bolt, spring, pressure regulation spring, upper spring, base plate,

nozzle partner and compaction nut

z Injector Type: low inertia, multi-hole and closed type z Nozzle Type: length needle valve type

Injector 1injector nozzle matching parts2shim3pressing nut 4supporting plate5spring bottom seat6pressure regulation spring7injector body8spring top seat9pressure regulation bolt10O-type sealing ring11locking nut12protective cap13inlet fuel pipe joint14rectangle rubber shim 15sealing ring


z Needle diameter: 8mm z Needle lift : 0.60.03mm z Seal seat angle: 60 z Hole diameter X number : 0.5mm8 z Angle of the hole: 150 z Starting injection pressure: 26MPa

7.5 Cooling water system

The cooling water system adopts two separate circle systems, one for the

high-temperature circle system., the other for the low-temperature. The high

temperature cooling water system cools diesel engine and turbo-charger, and

adopts pressure enclose circulation; The low temperature cooling water system

cools pressure gas in the diesel engine and the circle system of lubricating oil. It

consists of diesel engine, high temperature water pump, low temperature water

pump, inter-medium cooling, lubricity oil heat exchanger, cooling equipment,

expansion tank, valves, instruments, etc. The cooling capacity shall meet the

Iranian weather condition.


High temperature cooling cycle

Low temperature cooling cycle


7.6 Main frame assembly

Main frame assembly consists of main frame, cylinder liner, main bearing cap,

main bearing, stud bolt for main bearing and cylinder head, front oil seal, rear oil

seal, camshaft bearing and other inspection covers

Main frame Assembly 1Camshaft Bearing, 2Mainfiame, 3Cylinder Liner, 4Water Seal Ring of Cylinder Liner, 5Front Oil Seal,

6Oil Filling assembly, 7Crankcase Explosion Proof Door, 8Inspection Cover, 9Side Bolt, 10Stud for Main Beairng and Cylinder Head, 11Upper Main Bearing, 12Lower Main Bearing,


7.7 Crankshaft assembly

Crankshaft assembly including crankshaft, counterweight, counterweight screw,

location pin and oil plug. It is a steel forging, normalized and heated to improve its

physical properties.

7.8 Connecting rod assembly

Connecting rod is one of the most important moving parts and transforms

reciprocate of piston into rotate of crankshaft. On working condition connecting

Connecting rod assembly 1-small end bearing; 2- connecting rod upper bearing; 3-connecting rod lower bearing; 4-connecting rod bolt

1; 5-connecting rod bolt 2; 6-connecting rod cap; 7-sleeve; 8-screw plug; 9-connecting rod body


rod endures tensile stress, compressive stress and bending stress because of

explosion pressure and inertia force.

Connecting assembly is composed of connecting rod body, connecting rod cap,

small end bearing, connecting rod bearing and connecting rod bolt

7.9 Camshaft assembly

Camshaft assembly consists of camshaft, push rod unit, tappet unit, the function

of that assembly is to drive inlet valves, exhaust valves and injection pumps.

Camshaft is made of forge steel, the heat treatment of camshaft is carbonized and

quenching. Two-camshaft units mount to camshaft bore of mainframe, which

locate at each bank side individually. Each camshaft unit has four sections and

one thrust journal, i.e. two cylinders in one section. Every camshaft section marks

with serial number

Camshaft 1First section of camshaft; 2Second section of camshaft; 3Third section of camshaft; 4Fourth section of camshaft.


7.10 PGMV governor

16V280ZJA diesel engine adopts PGMV governor. It is well performance and

produced by Woodward (Tianjin) controls Co., Ltd

PGMV Governor 1Load control floating lever assy.2Start limit fuel lever assy.3Shutdown nut4Locknut5Speed setting assy.6Speed setting seat7Speeder spring8Pilot valve assy.9Vane servo assy.10Cover assy.11Column assy.12Power case assy.13Buffer cylinder plug14Buffer spring15Buffer piston16Spring seat17Base assy.


7.11 Turbo charge system

The function of the turbo charge system is making use of energy of the exhaust

gas, which has high pressure and temperature discharged from cylinder. It

transmits the exhaust air from cylinder exhaust outlet into turbine of the

turbocharger, and exhaust gas expands and forces the turbine to rotate, then the

compressor on the other end of the shaft joining turbine and compressor rotates

with turbine. By means of this, air pressure flowing through compressor is

increased and the air inhaled into cylinder is also increased, so, much fuel can be

injected into the cylinder and the engine output power is finally increased.

Classify according to structures of the exhaust pipes, there are two types of diesel

engine turbo charge system: constant pressure turbo charge and pulse turbo

charge. For constant pressure turbo charge system, all exhaust air is transmitted

PGMV work principle


a large-capacity exhaust manifold, which can steady the exhaust gas flowing into

the turbine. This system has high pressurization efficiency, and it fits to the diesel

engine operated long time under a high load case. When operated under the low

load case, because of the large capacity of the exhaust manifold, the pressure

changes gently and turbocharger reacts slowly, bad acceleration, purge

interference and big temperature differences between each cylinder. In pulse

turbo charge system, the exhaust manifold is short and thin, so the pressure

changes sensitive and greatly, and the pressure pulse energy of the exhaust gas

can be used sufficiently. So pulse turbo charge system fits the diesel engine

operated under the low load or under the variable operating condition.

The MPC (module pulse converter system) turbo charge system is used on diesel

engine 16V280ZJA. It has simple structure and good benefit of above systems.

The MPC turbo charge system consists of MPC exhaust pipe, turbocharger

VTC254, ABB, intercooler and air inlet piping.

Charging system of diesel engine16V280ZJA 1exhaust manifold , 2turbocharger , 3intercooler , 4intake manifold.


AB

B V

TC25

413

Tur

boch

arge

r


7.12 Main characteristic curves of engine

16V280ZJA engine load characteristic curve


16V280ZJA engines BSFC-speed curve


Engines torque-speed curve


7.13 Other main parts of engine

Piston Assembly 1-piston ring with barrel faced; 2-taper faced ring; 3-oil control ring; 4-piston crown; 5-O ring; 6-pin; 7-piston skirt; 8-piston

pin; 9-plug; 10-circlip 55; 11-circlip 110; 12-stud; 13-elastic sleeve; 14-nut; 15-clip.


Gear transmission mechanism 1-camshaft gear; 2-smaller timing idle gear; 3-larger timing idle gear; 4-crankshaft gear; 5-water pump gear;

6-oil pump idle gear; 7-oil pump drive gear



Timing system 1camshaft; 2tappet assemble; 3indicate valve; 4push rod sleeve; 5cylinder head; 6tappet assemble; 7rock arm; 8cylinder head cover; 9collect; 11rock arm bracket bolt; 12rock arm adjust screw; 13cross arm; 14cross arm spring; 15cross arm guide; 16outer valve spring ; 17inner valve spring; 18valve; 19valve guide; 20valve seat; 21lock nut; 22O-ring; 23injector sleeve; 24copper washer.


The fine filter 1rubber washer2down fuel seal washer 3filter body4filter core5crust 6filter shaft7upper fuel seal washer


Control toggle arm assembly 1rack clamping assembly 2positioning bracket3left vertical toggle arm4left and right tumblers5positioning bracket6across toggle arm7roll axis8adjusting arm9rocker10rocker 11spring toggle arm12limit block13adjusting bolt14emergency stop long arm

Copper intercooler of KLQ series structure 1-water inlet end shield , 2-gasket , 3-tube sheet , 4-side sheet , 5-water outlet end shield , 6finned tube.


Water pump 1forward cap of pump body ; 2pump body; 3bushing; 4impeller; 5bolt; 6nut; 7shaft; 8mechanical seal assembly; 9oil seal; 10rolling bearing; 11bushing (1); 12rolling bearing; 13bushing (2); 14cover; 15gasket; 16pump gear; 17nut.


8 AUXILIARY SYSTEM

8.1 Overview

The auxiliary system consist of auxiliary transmission system, ventilation system,

and Air filter system.

The function of auxiliary transmission system in the locomotive is providing the

power for the auxiliary equipment and the electric equipment.

Documents

Spek Tek Lokomotif Iran