Professional Documents
Culture Documents
DECLARATION ........................................................................................... 2
3 PERFORMANCE ....................................................................................... 28
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
5.9 FOUNDATION BRAKE RIGGING ........................................................... 51
5.10 DRAW GEAR ................................................................................. 54
5.11 FLANGE GREASER ......................................................................... 54
5.12 DAMPER ...................................................................................... 55
5.13 ACCESSORIES .............................................................................. 56
7 DIESEL ENGINE........................................................................................ 68
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
7.12 MAIN CHARACTERISTIC CURVES OF ENGINE ..................................... 83
7.13 OTHER MAIN PARTS OF ENGINE ...................................................... 86
8 AUXILIARY SYSTEM................................................................................. 92
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
14 MAJOR SUPPLIER INFORMATION...................................................... 135
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
DISCLOSURE NOTICE
Potential clients should abide by the foregoing since the receipt of the document.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
DECLARATION
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.
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Manufacturer: 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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
General layout
1air dryer2auxiliary converter ; 3cooling fan4fan motor5radiator6expansion tank7exhaust
pipe8diesel engine9main alternator10dynamic brake device11main silicon rectifier12air
conditioner13coupler14--traction motor15front blower(1)16excitation motor17main reservoir
18fuel tank19battery20start oil pump21heater exchanger22oil filter23rear blower24bogie
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25hand brake device26sand box27air compressor 28auxiliary generator; 29rear transmission gear
box 30air filter31start motor32front transmission gear box33front blower(2)34low voltage cabinet
35high voltage cabinet36driver chair;37console
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.
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
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
with former.
Air conditioner is installed on the ceiling board at the end of cab I and cab II.
The upside of the electric room is the air passage of front blower.
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.
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1.3.4 Cooling room
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.
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
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
2.2 Key technical data
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
2.3 Key basic technical data of locomotive
1 Gauge 1435mm
amendment.)
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
369kNTraction motor capacity
b) Continuous Effort
347kNAdhesion capacity
Wheelbase
a) Wheelbase 1800mm
c) Total Wheelbase of
15900mm
Locomotive
Locomotive Dimensions
a) Length Between
22220mm
Coupler Pulling Faces
14
3025mm (Total width including handrail, mirror etc)
b) Width
2950mm(Width of car-body)
c) Height 4650mm
Capacity of engine
17 1200L
cooling water
Centerline Height of
+5
19 1040 0 mm
Coupler above rail
Centerline Height of
+5
20 1060 0 mm
buffer above rail
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
2.4 Technical data of Key parts of locomotive
2.4.1Engine
Table 4
1 Model 16V280ZJA
Direction of rotation
9 Clockwise
(facing output end)
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
15 Firing pressure 13.72MPa
2.4.2Bogies
Table 5
2.4.3Synchronization generator
Table 6
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
7 Rated speed 1000 r/min
8 Excitation mode Separate excitation
Forced ventilation (Ventilation quantity is 270
9 Cooling mode
m3/min)
10 Rated efficiency 96.5
11 Insulation class H/H
2.4.4Traction motor
Table 7
2.4.5Starting generator
Table 8
1 Model ZQF-412
2 Rated power 80 kW
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
4 Rated current 728 A
Excitation capacity
7 Excitation voltage105 V, Excitation current8 A
(Generator condition)
13 Weight 850kg
Table 9
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
Table 10
1 Model JF417SX1
7 Number of phases 3
15 Weight 1100kg
Table 11
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
2.4.9Blower motor
Table1 2
Table13
Table 14
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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
Table 16
Table17
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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
2.4.15Air conditioner
Table 18
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
2.4.16 Electric Heater
Table 19
2.4.17Cooling equipment
Table 20
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
2.4.18 Main alternator Blower
Table 21
Table 22
Table 23
1 Type: JZ-7
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
7 Cooling method: Air
Air dryer
1 Model: SJKGC1
2 Quantity 1
3 Dispose capacity 5m3/min
4 Relative humidity (RH) 15%
Ambient temperature
5 -40+50
limit
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
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
3 PERFORMANCE
3.1 Horsepower
UintkW
The power of engine will not be needed to be modified, when the elevation is
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
NOTE:
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
3.4 Hauling Capacity of Loco Against Different Gradients
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
4 CAR BODY
4.1 Overview
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.
There are two doors respectively located on the side of the driver cab for the
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
The auxiliary room will be placed in between the driver cab II and cooling room.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
A ladder will be mounted in the auxiliary room for driver and assistant to get on &
off the locomotive top.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
4.19 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.
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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4.21 Major material of the car body
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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
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
The bogie consists of bogie frame, axle box, wheel set, motor suspension gear,
secondary suspension mechanism, foundation brake rigging, draw bar and
accessories.
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
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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.
hanger;7upper pull rod seat;8lower pull rod seat;9side bearing seat;10brake seat;11rear
1front end beam;2side beam;3damper seat;4crank-arm seat;5cross beam;6motor
end beam.
Frame
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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;17
space ring ;18rolling bearing;19outer cover.
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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.
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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.
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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.
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.
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Side bearing
1Metal-rubber sandwich block2lateral oil damper
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.
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Brake rigging schematic arrangement
1QB-7 brake unit; 2QB-7S brake unit
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
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;16
guiding nut;18flat key;19guiding nut sleeve;20pressing ring;21resetting retainer ring;22
clearance adjusting block;23end cover;24block sleeve;25screw rod;26pin shaft;27
spring; 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.
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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.
Draw Gear
1draw bar,2crank arm, 3connecting rod, 4dust plate, 5dust ring, 6separating sleeve, 7
draw pin, 8grease cup, 9brace, 10bolt, 11gland, 12spherical plain bearing,13draw
bar pin, 14nut, 15separating sleeve, 16cushion, 17connecting rod pin, 18crank arm pin
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
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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.
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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.
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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.
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.
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6.2.1Air Compressor
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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.
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.
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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
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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: <3s;
The time the brake cylinder is increased to the highest pressure after the
emergency brake: 47s;
The highest pressure of brake cylinder after emergency brake: 420450kPa;
Property of independent brake:
1) The highest pressure of brake cylinder under full brake position: 300kPa;
2) The time the brake cylinder is increased from 0L to 280kPa under full brake
position: 23s;
3) The time the brake cylinder is decreased from 300kPa to 35kPa under
operation brake position: <4s
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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.
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.
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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.
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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.
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.
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7 DIESEL ENGINE
7.1 Overview
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.
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16V280ZJA Engine configuration
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16V280ZJA Engine cross-section
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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..
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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
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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
Injector
1injector nozzle matching parts2shim3pressing nut
4supporting plate5spring bottom seat6pressure regulation spring7injector body8spring top seat
9pressure regulation bolt10O-type sealing ring11locking nut12protective cap13inlet fuel pipe joint
14rectangle rubber shim
15sealing ring
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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
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.
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High temperature cooling cycle
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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
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7.7 Crankshaft assembly
Connecting rod is one of the most important moving parts and transforms
reciprocate of piston into rotate of crankshaft. On working condition connecting
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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
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.
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7.10 PGMV governor
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.11
Column assy.12Power case assy.13Buffer cylinder plug14Buffer spring15Buffer piston16Spring
seat17Base assy.
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PGMV work principle
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
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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.
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ABB VTC25413 Turbocharger
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7.12 Main characteristic curves of engine
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16V280ZJA engines BSFC-speed curve
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Engines torque-speed curve
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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.
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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
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Timing system
1camshaft; 2tappet assemble; 3indicate valve; 4push rod sleeve; 5cylinder head; 6tappet assemble; 7
rock arm; 8cylinder head cover; 9collect; 11rock arm bracket bolt; 12rock arm adjust screw; 13cross arm; 14
cross arm spring; 15cross arm guide; 16outer valve spring ; 17inner valve spring; 18valve; 19valve guide;
20valve seat; 21lock nut; 22O-ring; 23injector sleeve; 24copper washer.
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The fine filter
1rubber washer2down fuel seal washer
3filter body4filter core5crust
6filter shaft7upper fuel seal washer
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Control toggle arm assembly
1rack clamping assembly 2positioning bracket3left vertical toggle arm4left and right tumblers
5positioning bracket6across toggle arm7roll axis8adjusting arm9rocker10rocker
11spring toggle arm12limit block13adjusting bolt14emergency stop long arm
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Water pump
1forward cap of pump body ; 2pump body; 3bushing; 4impeller; 5bolt; 6nut; 7shaft; 8
mechanical seal assembly; 9oil seal; 10rolling bearing; 11bushing (1); 12rolling bearing; 13bushing (2);
14cover; 15gasket; 16pump gear; 17nut.
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8 AUXILIARY SYSTEM
8.1 Overview
When the locomotive meets the condition of starting the diesel engine, the storage
cells supply electric energy to the starting generator, and the diesel engine is
driven to start by the starting generator via mechanical transmission mechanism.
Then the diesel engine directly drives the starting generator.
The ventilation system incuding the ventilation for power room, alternator and
traction motors.
The hot air will drain into the power room and take away by two exhaust fans.
The ventilation for power room insure the heat air can be take away from the room,
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and keep the inside temperature of the power room within a suitable value,
especially in hot weather of desert region.
The ventilation for traction motors equiped with blowers to force air to flow through
main silicon rectifier device and traction motors, to take away the heat produced in
working conditions. This could ensure the temperature rising of traction motors,
electric apparatus within specified ranges, and guarantee them to work normally.
To meet the operating requirement of diesel engine, the air filter of the locomotive
consists of double steps. Namely, outside gas First stage filtering (Inertia-type
air filter) the second stage filtering (Paper air filter) the turbo charger of
diesel engine.
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8.5 Lubricating oil filter
The lubricating oil filter is one of the most important parts of lubricating oil system.
It is used to clean out all kinds of harmful impurity and particulates in lubricating oil
and keep oil certain cleanliness in order to insure diesel engine runs reliably and
persistently.
The lubricating oil filter composed of gland, middle cover, end cover, filter shell,
filter core, magnetic steel, shaft, twin needles pressure gauge, related pipes,
joints, fastens, O-rings and etc
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8.6 Oil heat exchanger
Lubricating oil heat exchanger composed of cover one, cover two, barrel body,
fixed pipe plate, baffle plate, movable pipe plate, seal piece, fastens and etc
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8.7 Radiator
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8.9 Cooling fan
The fan is whole cast aluminum structure and the shaft sleeve is connected with
cast aluminum fan by bolts
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Outline cooling fan
1Shaft sleeve;2Streamline cover;3Cast aluminum fan.
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water is filled into diesel engine, air in water side of intercooler should be drained
out to atmosphere through expansion tank.
The body of expansion tank is welded with various kinds of steel plates. It is
divided into many water cavities through separator plate. Larger water ports are
set at top/bottom of separator plate to guarantee flow smoothly. It is mainly
composed of mounting seat, overflow pipe, water gauge, minimum water level
marking, separator plate, upper plate, exhaust pipe, inspecting opening cover,
water inlet, safety valve and so on.
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9 ELECTRIC DRIVE, ELECTRIC CONTROL SYSTEM AND
SAFETY APPARATUS
9.1 Overview
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ventilator used for the traction motor of bogies. The cooling air is sucked from two
sides of cubicle, passes through the suction opening of the ventilator after cooling
the rectifier cell and enters the main generator.
Six traction motors typed ZD109E are mounted in the locomotive to be supplied to
RAI. The traction motor is designed with a structure of four field poles, forced draft
mode and series excitation DC. The stator frame is pressed and welded from
eight sides by armor plate. The observation windows including two big ones and
two small ones are mounted at the commutator end of mounting base in order to
replace the electrical brush and maintain the commutator and brush holder. The
two ends of the traction motor are equipped with roller bearings and the bearings
should adopt the special grease for locomotive traction motor bearings. The stator
includes four main poles and four additive poles. The pole coil is bulk structure for
better heat emission. The main pole core is designed with lamination structure.
The air gap between the main pole core and armature core is noncircle for better
commutating capability. The additive pole core is made of solid forged steel. In
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order to fasten coils of main and additive poles, the liner part of coil and core is
filled with felt, the two ends are filled with insulation material and spring planks are
set between them. The whole stator is dipped in insulating varnish to integrate the
coil, core and mounting base into one unit to guarantee the running reliability of
motor. The armature is composed of armature coilsequalizersfront axial sleeve
back axial sleevecorecommutatorback bracket and shaft, etc. Coils and the
ends of equalizer are jointed with commutator by argon arc welding, which
guarantees the excellent electrical properties and mechanical performance of the
welding joints. The Teflon bracer is sticked to the extension part of the V-shaped
mica ring of commutator in order to enhance the welding resistance and the
sealing and dampproof performance of the commutator. The armature coils are
seized by steel wire and dipped by insulating varnish in vacuum container in order
to improve the integrity, sealing performance and reliability of armature. The brush
system includes four lean brush holders and each brush holder includes three
two-split brushes and is fixed on stator frame by brush staff. In order to improve
the arc welding resistance, the brush staff is covered with Teflon tubing.
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9.5 Revolution Speed Transducer
There are six rotating speed transducers (TQG2B) installed separately on six
motors, which are used to measure speed of the motor, the speed will be used to
not only show on the display but also control the locomotive. According to
electromagnetic induction theory, when top of the measured gear (m2.5
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20z68distance between top of gear
and terminal of transducer is 1.2mm) run
through terminal of transducer, coils set on
magnetic circuit will induce electric
potential, and then it will be enlarged by
electrical circuit, finally, the transducer will
output square wave pulse. The microcomputer will measure the rotating speed by
measuring number of impulse.
In order to supply the necessary signal to locomotive speedometer, a rotating
speed transducer is installed on the left
outboard of third axle box, the signal is
also very important for motor plugging
protection. It is an photoelectric rotating
speed transducer with four channels and
200 impulses per round, and its installation
dimension is (1300.1)mm,49mm,
the holes are evenly distributed. The
interface of transducer and wheel axle
drive is square junction holes 19+0.519+0.5mm, and the length of the drive
shaft is 110mm
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control equipments are equipped to adjust the excitation control of exciter. When
the locomotive is put into service, the power of diesel engine can be exploited
economically and the locomotive can exert large traction force and broad constant
work speed range.
The adhesion control system is in close connection with the revolution speed of
traction motor. One revolution speed transducer is installed on the axle head of
each traction motor commutator to measure the revolution speed of traction motor.
The microcomputer detects the entire revolution speed signal continuously and
makes certain comparisons. If the speed difference is larger than the preset
limiting value, the protective correction will be implemented.
When the locomotive conducts emergency braking or the rail surface adhesion is
relatively poor, the microcomputer will automatically switch on the sanding
electromagnetic valve and blast sand to the rail surface with high-pressure
process and increase the adhesion of the locomotive. The driver can also make
judgments from the rail surface conditions and artificially control the foot switch to
switch the sanding electromagnetic valve and complete the sanding operation.
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measures include alarming (indicator light), recording the fault, decreasing the
load of diesel engine, shutting down of diesel engine, and operating the logger.
When the locomotive failure is removed, the EXP will adopt corresponding
resetting methods to reset the faulting part in accordance with the types of faults.
The main protective measures used on the locomotive are as following: main
silicon rectifier cabinet output over-current, main silicon rectifier cabinet output
over-voltage, alternator whole over-current, alternator excitation over-current,
traction motor over-current, traction motor field current over-current, traction
motor runaway speed, traction main circuit earth connection, traction main circuit
over-current, and auxiliary generating over-voltage.
The main protective measures for the diesel engine including: Overpressure of
crankcase, Over-speed of diesel engine, Water temperature of diesel engine is
high, Oil temperature of diesel engine is high, Over-speed of diesel engine front
turbocharger, Over-speed of diesel engine rear turbocharger, Low engine oil
pressure, Low pressure of fuel system terminal, Inter-locking of crank shaft, Etc.
9.10 Battery
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over-discharging, easy starting, light weight, and long service life.
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1-phoenix terminal;2-left door groupware;3-door lock;4-electric
heater;5-foot switch;6-general changeover switch(1SA);7- general
changeover switch(18SA);8- general changeover switch(3SA);9- general
changeover switch(6SA);10- general changeover switch(15SA);11-
general changeover switch(9SA1-2);12-electric instrument
module;13-consist telephone;14-LCS32-displayer;15-wind instrument
module;16- ashtray;17-fore four toggle switch groupware;18-master
controller;19-button(stop);20-button(shunting);21-button(1SB2);22-button
(1SB1);23-button(1SB3);24-button(1SB4);25-twelve toggle switch
groupware.
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9.11.5 Electric apparatus control cabinet
The electric apparatus control cabinet is in electrical cab.
The electric apparatus in the electrical cabinet completes all the control orders
that the driver sends.
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This interlock makes sure the operation of locomotive is completed safely and
reasonably.
Push the main handle from 0 notch to 1 notch, and the direction changing switch
starts to work. Through all
the electric apparatus
interlock control, the
excitation circuit of the
locomotive exciter, main
circuit and main alternator
excite circuit can be turned
on, and main alternator
provides power to traction
motor to start running of the
locomotive.
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diesel oil over-temperature protection and so on.
The oil pressure protection of the diesel engine by computer control can be
canceled or modified by software or hardware.
When the current of over-current relay loop surpasses the stated value, the
earthing relay start working and the diesel engine is unloaded. Earthing failure
has two alarming modes: earthing signal lamp and computer LCD display.
When the current in main circuit surpasses the stated value, over-current relay
starts working and the diesel shall be unloaded. Over-current failure has two
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alarming modes: over-current signal lamp and computer LCD display.
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9.11.9 Lighting
The locomotive lighting consists of the head lighting, the cab lighting, the car body
inside lighting and the car bottom lighting. All of the lightings shall be controlled by
the lighting switch fixed no the electric apparatus cabinet. When putting the
lighting switch on the position of battery, the power for lighting is supplied by the
battery before the diesel engine starts running; after the diesel engine starts, the
lighting circuits electricity shall be supplied by DC starting generator; when
putting the lighting switch on the position of external power source, the
lighting circuit is connected with the external power source outside of locomotive
through locomotive power socket.
The marker lights (signal lamp) will be designed according to UIC534 standard.
The headlamp adopts halogen tungsten lamp with power 800W, does not need
trigger and can be started directly; the mark lights consists of electro optics light
with power 200W and incandescent lamp.
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9.11.9.2 Drivers cab lighting
The drivers cab lighting consists of the top cab lamp, and the operating console
lamp. The top cab light is composed of a group of mixed bulbs, and the operating
console lamp adopts incandescent light.
The dead man device will be designed and produced in accordance with UIC641
standard, every sixty seconds the driver must press the button of dead man
device on the operating console, if exceeding the stated time, the did not do this
work, then the vigilance system shall send a alarm to warn the driver to pay
attention. If still no action occurring (normally, after ten seconds), the
microcomputer will control locomotive unload the diesel engine and apply the
emergency brake.
The proposed locomotive has capability of coupling two (2) locomotives and also
controlling these locomotives from one cab. The locomotive will use cable multiple
unit operation by controlling the switching value. The locomotive shall be
equipped with entire microcomputer control system and can control all these
locomotives from one cab.
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9.14 Dynamic brake device
The proposed locomotive for Iran shall equip the dynamic braking with full
self-loading function and adjusting the speed of train on the long down gradient.
The principle of dynamic braking is that use the dynamic braking device to
consume the electricity power that generated by alternator or traction motors
during the self-loading or adjusting the speed of train to heat power.
The locomotive will supply the data output function. All the necessary information
that the microcomputer system has recorded can be output via the hardware
interface.
The running data recorder can continuously record almost all the information of
the locomotive running status. It can repeatedly record the data and show in files
depended on hour. The recorder can continuously record the data for 200 hours;
during that the whole distance can be more than 3000km. The operator can
deliver all the data from the recorder to PC through a special flash disk, and then
read it out by an analyze software. It can help the operator to analyze the
locomotive failure mode or maintain the parts and components of the locomotive,
the data can also be printed in type of sheet.
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9.16 Electric diagram
9.16.1 Main Circuit
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9.16.2 Multiple Unit Circuit
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9.16.3 Computer Interface
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9.16.4 Main Silicon Rectifier Circuit
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9.16.6 Switching diagram of operating mode
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This blank page is left here intentionally for any amendment
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10 DRIVER CAB AND ACCESSORY EQUIPMENT
10.1 Overview
The equipments and the components arranged in the locomotive are convenient
for maintenance.
The space inside the locomotive is spacious for operation and the colour of the
interior decoration and facilities are harmonious and comfortable. The lighting
system has perfect control of full light and half-light. The cab provides many
instruments, such as the speed recording equipment and failure indicating
equipment. Also, the cab provides HVAC system, hot plate and refrigerator. The
cab is designed to be vibration proof and noise proof. All above will provide a
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good operating environment for the drivers.
The cab accommodates two regular seats for the driver and assistant.
10.2 Seats
The operators cab shall be equipped with the side windows and forward window.
The side windows shall be placed on the upper place of the sidewall of the cab.
The side windows shall be bi-directional, one-piece sliding with two stationary at
the each end. The glass used for the side windows shall be tinted gray by 30%
transmissibility of visible wavelengths and be able for the workers to lock the
windows inside the cab with the lock and the cam lock. The windows shall be of
proper sealing performance.
The door of the cab shall be made by the way of mould. The door shall be of
perfect rigidity and plainness, and seal strip mounted along the edge of the door
will help to seal. The door shall be equipped with lock and the lock shall be
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opened & locked with the key outside and be locked & unlocked without the key
inside. And the door can also be fastened by cam lock inside the cab.
In the cab, there shall be HVAC system according to UIC 651. All these devices
shall be separately settled and shall be removable.
The strip heaters shall be placed separately under the side windows and in front
of the feet of the driver and the assistant driver, during the winter, the drivers can
use these heaters as help for air conditioner to warm the driver cab.
10.5.2 Fans
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
The air conditioning equipment shall be used
for cooling. The outlet of cooling air shall be
placed on the partition. The volume and
temperature shall be adjusted through control
panel that is mounted on the partition wall.
The direction of cooling winds shall be
changed through adjusting the outlet shutter
manually.
10.6 Floors
The floors are made of iron-frame and wooden structure, the surface of the floors
shall be covered with a resilient material that is resistant to water, oil penetration
and fire propagation. And the surface shall be non-skid.
10.7 Ceilings
The locomotive operators cab shall be designed for the good performance of
sound & heat insulation. More efforts shall be performed on the materials, the
design of the doors and windows and the sealing components mounted on them.
The cab shall be as quiet as 80dB (A) with our sound insulation system.
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10.9 Coat Hooks
The cab accommodates five beautiful and durable coat hooks on the rear
partition.
The signal flag box will be placed on the partition wall of the auxiliary room
10.12 Refrigerator
The locomotive will supply the rearview function. Such as the rearview mirror...
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10.14 Foldable seat
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11 PAINTING
The variety and color of the paint of each part are as follows:
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Note:The colour of the paint execute the international (Europe) colour standard.
Thereinto:
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
12 STANDARDS
12.1 General
During design and manufacturing of the locomotive, QS will adopt the relevant
railway standards. High-level quality control system will be put into use in the
project. Except special requirement stated in the specification arouse from the
client, locomotive design, manufacturing and test will be in compliance with one of
the following standards.
z The International Union of Railways Standards (UIC)
z International Organization for Standardization (ISO)
z International Electro. Technical Commission Standard (IEC)
z Standard of MOR of the Peoples Republic of China (TB)
z National Standard of the Peoples Republic of China (GB)
z German Standards of Material and Specification (DIN)
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
11 ISO 3046.1-2002 Power derate of engine
12 GB/T5780-2000 eqv ISO4016:1999 bolt
13 GB/T5782-2000 eqv ISO4014:1999 bolt
14 GB/T6170-2000 eqv ISO4032:1999 nut
15 GB 4728 -2005 eqv.IEC 617 Graphical symbols
16 TB/T 1333.12002 eqv.IEC 60077-11999 Electric equipment for
rolling stock Part1Generral service conditions
and general rules
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13 VENDORS LIST OF MAIN WEARABLE PARTS
Diesel Engine
Beijing Nankou
1 Fuel injector module
Zhejiang Liwei
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
Air compressor motor carbon
6 Xian Motor Factory
brush
Bogie
Brake
Beijing Nankou
Auxiliary system
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
14 MAJOR SUPPLIER INFORMATION
No Item Supplier
Diesel Engine
Diesel engine general
1 CSR Qishuyan locomotive Co.,Ltd
assembly
2 Engine body CSR Qishuyan locomotive Co.,Ltd
3 Turbocharger ABB jiangjin turbo systems Co., Ltd
4 Governor Tianjin WDO Co.
5 Main lubrication oil pump Beijing Nankou Co.
6 Crank shaft CSR Qishuyan locomotive Co.,Ltd
7 Cam shaft CSR Qishuyan locomotive Co.,Ltd
8 Connecting rod CSR Qishuyan locomotive Co.,Ltd
General assembly of
9 CSR Qishuyan locomotive Co.,Ltd
cylinder cover
General assembly of
10 CSR Qishuyan locomotive Co.,Ltd
cylinder liner
11 Water pump CSR Qishuyan locomotive Co.,Ltd
12 Connection equipment CSR Qishuyan locomotive Co.,Ltd
13 Coil spring damper CSR Qishuyan locomotive Co.,Ltd
Electric motor and electric system
CSR Chengdu Locomotive&Rolling Stock Co.,Ltd
1 Main alternator
CNR Yongji Electric Machine Factory
CSR Chengdu Locomotive&Rolling Stock Co.,Ltd
2 Traction motor
CNR Yongji Electric Machine Factory
CNR Yongji Electric Machine Factory
3 Blower motor
CSR Chengdu Locomotive & Rolling Stock Co.,Ltd
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
CSR Zhuzhou Electric Machine Factory
CSR Xiangfan traction motor Co.,Ltd
4 Start motor
CSR Zhuzhou Electric Machine Factory
CSR Chengdu Locomotive&Rolling Stock Co.,Ltd
5 Auxiliary motor
CNR Yongji Electric Machine Factory
CSR Chengdu Locomotive&Rolling Stock Co.,Ltd
6 Cooling fan motor CSR Zhuzhou Electric Machine Factory
CNR Yongji Electric Machine Factory
Xian Railway Signal Factory
7 Electric cabinet
CNR Yongji Electric Machine Factory
CSR Zuzhou
8 Main silicon rectifier
Xian Ketian
Xian Railway Signal Factory
9 Console
CNR Yongji Electric Machine Factory
Major electric
10 Xian Schaltbau Electric Co.,Ltd
components
11 Microcomputer system Zhuzhou CSR Times Electric Co.,Ltd
Changzhou Xieshun Motor Trolley Compoonents
12 Dynamic braking device Co.,Ltd
Xian Railway Signal Factory
Xingxiang Taihang
13 Battery
Shiquan Changhong
Bogie
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
CSR Qishuyan locomotive rolling stock
5 Transmission gear
technology research institute LTD
General assembly of axle CSR Qishuyan locomotive Co.,Ltd
6
box
7 Foundation brake rigging CSR Qishuyan locomotive Co.,Ltd.
Brake
Tianjin Railway Vehicle Transportation Equipment
Co. Ltd.
1 JZ-7 air brake
Shenyang Locomotive & Rolling Stock Brake
Equipment Co., Ltd
Shijiazhuang Jiaxiang Precision Machinery Co., Ltd
2 Air compressor
Beijing Nankou Company
Qindao Zhongjian Comprehensive Technology
3 Air dryer Research Institute Co., Ltd
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Manufacturer: CSR Qishuyan Locomotive Co.,Ltd.
1 Cooling system CSR Qishuyan locomotive Co.,Ltd
Dalian tongtie thermodynamics Co.,Ltd
2 Radiator
Wuxi Dongjiang
Hangzhou Railway Motors Factory
3 blower
Changzhou Wuyi
Weihai Creditfan Ventilator Co.,Ltd
4 Cooling Fan Dalian Science & Technology Research Institute
Changsha Company
5 Transmission gear box CSR Qishuyan locomotive Co.,Ltd
6 Lubrication oil filter CSR Qishuyan locomotive Co.,Ltd
Lubrication oil heat
7 CSR Qishuyan locomotive Co.,Ltd
exchanger
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