Spek Tek Lokomotif Iran

Technical Specification of Freight Locomotive for Iran Railway

(DF8BI)

CSR QISHUYAN LOCOMOTIVE CO., LTD. Feb. 2009

Page 1

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

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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

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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

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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

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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

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

Page 1


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.

Page 2


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 client’s 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.

Page 3


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.

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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 1984，and 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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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.

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

contour will be same as Iran locomotive’s 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

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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 RAI’s experts in design liaison phase.

The arrangement and the decoration of the cab Ⅰand the cab Ⅱ is almost

identical. The main differences lie in two point, A middle door is designed in

partition wall behind the cabⅠfor electric component maintenance; Hand brake

device that be only assembled in the middle of partition wall in cab Ⅱ. 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 driver’s requirement. Meanwhile there is

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

Page 9


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 Ⅰ for magnet valve and sensor of

brake system is at the contrary side.

At the upper part of the rear partition wall，there 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

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 it’s 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-Ⅱ, 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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This blank page is left here intentionally for any amendment

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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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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

Page 14


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 (23±0.69) 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 kN（Traction motor capacity）

440kN（Adhesion capacity）

Page 15


b) Continuous Effort 369kN（Traction motor capacity）

347kN（Adhesion 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.

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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 (length×width×height)

4867.5mm×1725mm×2895mm

12 BSFC ≤205+3% g/kW·h (under UIC condition)

13 Oil consumption ≤2.04 g/kW·h (under UIC condition)

14 Effective pressure 1.65MPa

Page 17


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 2×1800 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

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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 N·m 14 Continue torque: 7055.5 N·m 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

Page 19


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 voltage≤105 V, Excitation current≤8 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 A（15min）

5 Rectifier component type and quantities

ZPX3000-30 type, 12 pieces

6 Rectifier mode Three–phrase bridge type rectifier circuit

2.4.7 Auxiliary generator

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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

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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

Page 22


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 A·h 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 2×1750 kW

Page 23


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: （95±3）% (≥40℃)

10 Reliability: MTBF≥3000h

Page 24


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

Page 25


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-230DⅡ

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

Page 26


7 Cooling method: Air

Air dryer 1 Model: SJKG－C1 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 110±10V 9 Dryer unit weight 148kg

Page 27



Page 28


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:

Uint：kW The power of engine will not be needed to be modified, when the elevation is

Page 29


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:

ω’o=2.40+0.0022V+0.000391V2 (N/kN)

Rolling stock resistance formula

ω”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.

Page 30


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 it’s 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.

Page 31


Page 32


3.4 Hauling Capacity of Loco Against Different Gradients

Page 33



Page 34


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

Page 35


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 driver’s 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.

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4.7 Cooling room

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

of the sidewall, It’s 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.

Page 37


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.

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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 it’s 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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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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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.

Page 41


Page 42


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

Page 43



Page 44


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

Page 45


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

Page 46


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.

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Page 47


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

Page 48


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

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

Page 49


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)

1－dust guard ring（3）;2－dust guard ring（4）;3－driving bearing（1）TR483608SS;4－

big-end bolt;5－u-tube;6－small-end bolt;7－driving bearing（2）TR483205SS;8－adjusting

shim（1）;9－bearing seat;10－dust guard ring（1）;11－dust guard ring（2）;12－adjusting

shim（2）;13－gear case assembly;14－air ducts assembly;15－suspension link assembly;

Page 50


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

parts－the 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.

Page 51


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 4×M16

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 1－Metal-rubber sandwich block；2－lateral oil damper

Page 52


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

Page 53


QB－7S brake unit 1－ brake shoe;2－ inserted pin;3－ brake shoe pin;4－ brake shoe holder;5－ brake shoe supporting;6、7－nut;8－guiding sleeve; 9－case;10、17－adjusting spring;11－force-pushing retainer ring;12－51108 bearing;13－adjusting nut;14－lever;15－adjusting nut sleeve;16－guiding nut;18－flat key;19－guiding nut sleeve;20－pressing ring;21－resetting retainer ring;22－clearance adjusting block;23－end cover;24－block sleeve;25－screw rod;26－pin shaft;27－spring; 28－screw cap;29－pulling ring;30－guiding ring;31－rubber cup;32－release spring;33－ piston pushing pole;34 － fitting;35 － brake cylinder;36 － pin;37 － lock spring;38 －

51110bearing; 39－washer;40－pin shaft;41－dustproof cap;42－screw rod pin.

Page 54


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

Page 55


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.

Page 56


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.

Page 57



Page 58


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.

Page 59


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 750±20kPa, Stop working when the main reservoir pressure is higher than

900±20kPa.

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 water（because 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）.

Page 60


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 (950±20)kPa，and 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.

Page 61


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 30～40kPA when the

handle of automatic brake valve is located at over-relief position. The

over-charging pressure will be automatically relieved within 150～180s 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 45～55kPa.

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

Page 62


500kPa.

The times are 5～8s when the brake tube is reduced from the rated pressure of

500kPa to pressure of 140kPa.

The time is 6～9s when the brake cylinder of locomotive is increased from the

maximum pressure. The highest pressure of brake cylinder is 340～380kPa 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 5～9s 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: 4～7s;

The highest pressure of brake cylinder after emergency brake: 420～450kPa;

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: 2～3s;

3) The time the brake cylinder is decreased from 300kPa to 35kPa under

operation brake position: <4s

6.4 Sanding system

Sanding system is provided to improve the adhesion of the locomotive to prevent

the wheel sets from racing and sliding. The sand spraying system is composed of

sand boxes, sanding valve, electro magnetic valve, pressure relay and pedal

switch etc. to realize three performances as following:

Page 63


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.

Page 64


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.

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 rope，the rail will be

strained after changing force direction by block and tackle，then 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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Page 67



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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.

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16V280ZJA Engine cross-section

Page 71


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

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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 Type: low inertia, multi-hole and closed type

Nozzle Type: length needle valve type

Injector 1－injector nozzle matching parts；2－shim；3－pressing nut；

4－supporting plate；5－spring bottom seat；6－pressure regulation spring；7－injector body；8－spring top seat；

9－pressure regulation bolt；10－O-type sealing ring；11－locking nut；12－protective cap；13－inlet fuel pipe joint；

14－rectangle rubber shim；

15－sealing ring。

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Needle diameter: φ8mm

Needle lift : 0.6±0.03mm

Seal seat angle: 60º

Hole diameter X number : φ0.5mm×8

Angle of the hole: 150º

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.

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High temperature cooling cycle

Low 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

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

6－Oil Filling assembly, 7－Crankcase Explosion Proof Door, 8－Inspection Cover, 9－Side Bolt,

10－Stud for Main Beairng and Cylinder Head, 11－Upper Main Bearing, 12－Lower Main Bearing,

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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

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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

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

1－First section of camshaft; 2－Second section of camshaft; 3－Third

section of camshaft; 4－Fourth section of camshaft.

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7.10 PGMV governor

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

produced by Woodward (Tianjin) controls Co., Ltd

PGMV Governor 1－Load control floating lever assy.；2－Start limit fuel lever assy.；3－Shutdown nut；4－Locknut；5－Speed setting

assy.；6－Speed setting seat；7－Speeder spring；8－Pilot valve assy.；9－Vane servo assy.；10－Cover assy.；11

－Column assy.；12－Power case assy.；13－Buffer cylinder plug；14－Buffer spring；15－Buffer piston；16－Spring

seat；17－Base assy.；

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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

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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.

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

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7.12 Main characteristic curves of engine

16V280ZJA engine load characteristic curve

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16V280ZJA engine’s BSFC-speed curve

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Engine’s 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 1－camshaft; 2－tappet assemble; 3－indicate valve; 4－push rod sleeve; 5－cylinder head; 6－tappet assemble; 7－

rock arm; 8－cylinder head cover; 9－collect; 11－rock arm bracket bolt; 12－rock arm adjust screw; 13－cross arm; 14

－cross arm spring; 15－cross arm guide; 16－outer valve spring ; 17－inner valve spring; 18－valve; 19－valve guide;

20－valve seat; 21－lock nut; 22－O-ring; 23－injector sleeve; 24－copper washer.

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The fine filter 1－rubber washer；2－down fuel seal washer；

3－filter body；4－filter core；5－crust；

6－filter shaft；7－upper fuel seal washer。

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Control toggle arm assembly 1－rack clamping assembly； 2－positioning bracket；3－left vertical toggle arm；4－left and right tumblers；

5－positioning bracket；6－across toggle arm；7－roll axis；8－adjusting arm；9－rocker；10－rocker；

11－spring toggle arm；12－limit block；13－adjusting bolt；14－emergency 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 , 6－finned tube.

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Water pump 1－forward cap of pump body ; 2－pump body; 3－bushing; 4－impeller; 5－bolt; 6－nut; 7－shaft; 8－

mechanical seal assembly; 9－oil seal; 10－rolling bearing; 11－bushing (1); 12－rolling bearing; 13－bushing (2);

14－cover; 15－gasket; 16－pump gear; 17－nut.

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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.

The auxiliary transmission system consists of mechanism transmission, AC motor

transmission and DC motor transmission.

8.2 Auxiliary transmission system

The auxiliary transmission equipment is mainly composed of front transmission

gear box, start generator, cardan shaft, elastic rubber coupling, elastic ring

coupling etc; It is used for starting the diesel engine; The AC transmission use for

drive the blower and cooling fan and the DC transmission is used for driving the

air compressor, etc.

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.

8.3 Ventilation System

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.

8.4 Air filter system

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

The locomotive adopts double fluid passage radiator which is mechanical

expansion one.It is composed of coupling box, damping rubber plate, hose,

cooling flat pipe, radiating fin, side protecting plate and so on

8.8 Fuel pump

Fuel pump which is composed of discharg pipe, front cover, driven shaft, bearing seat, complex bearing, stop nut, toothed mat, levogyrate gear, lower dextrogyrate gear, rear cover, upper dextrogyrate gear, mat, retainer, flexible black lead ring(oil seal), driving shaft, gland, pump body and etc. Main technical parameters

Motor type ZTP-22 Speed 2200 r/min Flow 60 L/min Outlet pressure 0.5 Mpa

Vacuum 0.05 Mpa

Double fluid passage radiator 1－Coupling box;2－bolt;3－end plate;4-shim; 5－Cooling flat tube;6－Radiating fin;7－side protecting plate.

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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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8.10 Expansion tank

The function of expansion tank is to store the cooling water to make up the water (which is leaked and wasted when locomotive running) and drain the steam in high temperature cooling water away from diesel engine. It will avoid steam to enter into radiator to influence heat radiating capability of whole system. When

Outline cooling fan 1－Shaft sleeve;2－Streamline cover;3－Cast 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.

Expansion water tank 1－Mounting seat; 2－Overflow pipe; 3－Water gauge; 4－Minimum water level marking;5－Separator plate; 6－Upper

plate;7－Connecting syphon; 8－Low temperature exhaust pipe; 9－Inspection cover;10－Water inlet;11－Safety valve

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9 ELECTRIC DRIVE, ELECTRIC CONTROL SYSTEM AND SAFETY APPARATUS

9.1 Overview

The locomotive to be supplied to RAI is designed to be AC-DC locomotive. The

diesel engine directly drives one synchronous main generator to output

three-phrase AC. The AC is commutated by the main silicon rectifier cubicle and

feeds the six parallel-connected traction motors. The traction wheel is driven by

the motors through the transmission box of traction gear to pull the locomotive.

The traction works in the form of series excitation.

Primary field weakening will be adopted for the purpose of expending the range of

constant power.

9.2 Synchronous Main Generator

A three phase synchronous main generator is mounted in the locomotive to be

supplied to RAI. JF204D is horizontal single bearing and three-phase salient pole

synchronous alternator. At the slip-ring end, there is an E32626QTY single row

cylindrical roller bearing of collector ring, of which the shaft extension taper is 1:10,

and used to auxiliary transmission. Another end is connected with engine by

flexible shaft-joint. Forced draft along the axial direction is used to cool down the

main generator, the cooling air enters into the generator through the bottom air

inlet of end cover, after cooling down the generator along the axial direction, it will

be output from the other end.

9.3 Main Silicon Rectifier

The main silicon rectifier cubicle is composed of cubicle, DC copper bars, AC

copper bars, rectifier cells, wires and cables, and CR protective device. The

three-phrase AC copper bars enter from the top of cubicle, and the output DC

copper bars are led out from two sides of the bottom of cubicle. The mode of

rectification is three-phase bridge type. The mode of cooling is forced ventilation

draft. The cooling air ducts are parallel connected with the suction opening of the

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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.

9.4 Traction Motor

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 coils，equalizers，front axial sleeve，

back axial sleeve，core，commutator，back 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 (m＝2.5，α＝

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20°z＝68，distance 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 (φ130±0.1)mm,4×φ9mm,

the holes are evenly distributed. The

interface of transducer and wheel axle

drive is square junction holes （19+0.5×19+0.5）mm, and the length of the drive

shaft is 110mm。

9.6 Traction Control System

The controlling system of the locomotive adopts the complete microcomputer

logical control technology and double standby redundancy design. The control

system adopts big screen liquid crystal display and performs various functions of

fault detecting, alarming, diagnosis, recording and so on. It also provides overall

protection for traction constant power, anti-slippery and anti-sliding device, diesel

engine oil-water temperature, lubricating oil pressure, and the air pressure of

braking system. The limiting pressure still holds the line when the traction motor

fault is removed. The constant power and limiting current value will be reduced

1/6 respectively when each traction motor is cut down.

Double microcomputer excitations and fixed electricity generating excitation

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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.

9.7 Adhesion Control System

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.

9.8 Sanding Control

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.

9.9 Protection and Power Decrease System

The microcomputer continuously detects voltage, current, frequency signal of

locomotive electrical system and temperature, pressure signal as well as all kinds

of on-off input signals of diesel engine system, and then compares these data with

the preset threshold value. If the detected monitoring parameters exceed the

limiting value, a message informing the fault will be sent and displayed on the

screen, making the display screen enter into the fault display mode.

Simultaneously, the microcomputer control screen will provide certain protective

measures on the basis of the fault category and severity. These protective

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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.

Additionally, a speed recorder shall be equipped with the locomotive.

9.10 Battery

The battery is mainly used for starting

the diesel engine. Moreover, when the

auxiliary electricity is not available, it can

supply electricity for locomotive lighting

and traveling crane equipment. The

alkalescency battery GNC210 with super

rate has many merits such as that it can

withstand overcharging and

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over-discharging, easy starting, light weight, and long service life.

9.11 Control System

9.11.1 Wires and cables The type of locomotive main circuit electric power cables is Grade 750V DCJ with

low smoke, no bittern and high fire resistance.

Thin cables with light weight, fire resistance, low smoke, no bittern and good safe

performance are used as locomotive control cables

9.11.2 Power socket The sides of car body are equipped with battery charging socket and exterior power

socket.

9.11.3 Layout of control equipment Locomotive control equipment consists of driver’s desk and electric apparatus

control cabinet.

9.11.4 Driver’s desk The driver’s desk is located inside the operator cab. In front of the driver’s desk

are computer LCD and instruments etc. On the desk are master control and

switch group. Through these apparatus the driver can control diesel engine

starting, locomotive starting, running and stop. General changeover switch and

micro-breaker are installed on the door of the driver’s desk.

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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.

Main apparatus include main contactor, reverse changeover switch, working

condition changeover switch etc. Low voltage apparatus mainly consist of diesel

engine starting contactor, air compressor motor contactor, exciter contactor and

control apparatus, intermediate relay and general changeover switch etc.

The electric apparatus in the electrical cabinet completes all the control orders

that the driver sends.

9.11.6 Circuit control and protection Locomotive circuit is mainly composed of circuit power control, operating circuit

control and protecting circuit.

9.11.7 Circuit power control DC starting generator feeds the power circuit, and when the DC starting generator

is off, it is fed by battery.

9.11.8 Locomotive operating circuit control Locomotive operating circuit includes diesel starting, speed governing shut down

and locomotive starting, speed governing etc.

9.11.8.1 Diesel engine starting Press the “diesel engine starting” button to start the diesel engine.

9.11.8.2 Diesel speed governing The master controller includes direction changing handle and main handle. The

change direction handle has 3 positions: forward, backward, 0. The main handle

has 16 notches from 0 to16. Only when the main handle is on “0” notch, you can

change the position of the direction changing handle, and only when the direction

changing handle is on “0” position, you can turn main handle away from “0” notch.

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This interlock makes sure the operation of locomotive is completed safely and

reasonably.

9.11.8.3 Diesel shutdown A button will be fixed on the driver’s desk. Press the diesel engine stop button can

shut down the diesel engine.

9.11.8.4 Locomotive starting circuit Turn the direction-changing handle on the master controller to “forward” or “back”

position to prepare for the locomotive starting.

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.

9.11.8.5 Locomotive speed governing circuit By pushing the main control handle of the master controller to a higher notch, the

output power and the speed of diesel will increase, and then the speed of

locomotive will increase accordingly.

9.11.8.6 Locomotive protective circuit The locomotive protection circuit includes oil pressure protection, water

temperature protection, crankcase pressure protection, diesel over-speed

protection, earthing protection, over-current protection, over-voltage protection,

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diesel oil over-temperature protection and so on.

9.11.8.7 Oil pressure protection In order to ensure the correct lubrication of the diesel engine, it’s required that a

certain pressure should be kept to the lubricating oil system, and the oil pressure

should change when the load of diesel engine changes. If the oil pressure is lower

than the stated value, the diesel engine should be shut down. There are two

protection methods for the oil pressure of the diesel engine: oil pressure relay

control circuit and microcomputer control circuit. Alarming signal shall be

displayed on the LCD screen of the computer.

The oil pressure protection of the diesel engine by computer control can be

canceled or modified by software or hardware.

9.11.8.8 Earthing protection

The earthing protection circuit is composed of inspection circuit, earthing switch

and failure switch.

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.

9.11.8.9 Over-current protection Over-current protections include main alternator over-current protection, traction

motor over-current protection, main alternator excites over-current protection and

traction motor excites over-current protection.

9.11.8.10 Alternator over-current protection The circuit consists of current reactor, three phase bridge rectifier circuit and

over-current relay.

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.

9.11.8.11 Traction motor over-current protection When the locomotive is put into service, if the current of one traction motor

reaches the stated value, the traction power will be limited to 0, the computer LCD

display “traction motor over-current” and the computer alarming lamp lights.

9.11.8.12 Alternator excitation over-current protection When the locomotive is put into service, if alternator excitation current is over a

stated value, the computer LCD display “ alternator excitation over-current” and

the computer alarming lamplights.

9.11.8.13 Over-voltage protection 9.11.8.13.1 Auxiliary power over-voltage protection The locomotive starting generator has two modes of power generation: auxiliary

power generation and fixed power generation. Auxiliary power sources voltage is

adjusted by microcomputer. When the auxiliary power voltage is (125+5)V, the

“auxiliary power over-voltage” lamp lights and the starting generator turns to fixed

power generation.

9.11.8.13.2 Alternator over-voltage protection When the locomotive is put into service, if main rectifier’s output voltage is over

1100V, the computer limits the power to zero and the computer LCD displays

“main alternator over-voltage”.

9.11.8.14 Fire alarm system

The locomotive equips with the fire alarm system.

9.11.8.15 Fault display and disposal strategy

The example of fault disposal strategy is as following table.

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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 circuit’s 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.

9.11.9.1 Head lighting The locomotive head lighting consists of headlight and mark lights.

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 Driver’s cab lighting The driver’s 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.

9.11.9.3 Car body inside lighting The car body inside lighting includes the lightings for electrical apparatus room,

auxiliary room, air compressor room, and the scanty lamps are adopted for the

lighting.

9.11.9.4 Lighting under the under-frame The lighting under the under-frame adopts incandescent lamps, mainly used for

lighting when checking equipment under the car body.

9.12 Dead man device

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.

9.13 Multiple unit operation function

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.

9.15 Data output function

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

9.16.5 LCS32 microcomputer operating principle block diagram

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9.16.6 Switching diagram of operating mode

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10 DRIVER CAB AND ACCESSORY EQUIPMENT

10.1 Overview

The operator’s cab is designed to improve the locomotive operator’s working

environment and enhance productivity. More attention is paid to ergonomics and

safety concerns.

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

Two seats will be provided for the driver and the

assistant driver. The height, left-right and front-rear

direction of the seat can be adjusted for a large

range to meet the requirements of the driver and the

assistant driver.

The seats dimensions and ergonomics is subject to

RAI’s approval.

10.3 Windows and Glass

The operator’s 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.

10.4 Doors and Door Security

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.

The door shall be sealed and secured perfectly when locked.

10.5 HVAC System

In the cab, there shall be HVAC system according to UIC 651. All these devices

shall be separately settled and shall be removable.

10.5.1 Electric heaters

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

Two fans shall be mounted in front of the driver

and the assistant driver as well as above the

console and stand on the partitions. The speed

and the direction of the fans shall be controlled

separately. The ventilator can meet the

requirement of ventilation volume stated in UIC

standard.

10.5.3 Air conditioners

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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 ceiling of the driver cab will be lacunaris aluminium plate.

10.8 Sound & Heat Insulation Performance

The locomotive operator’s 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.

10.10 Signal Flag Box

The signal flag box will be placed on the partition wall of the auxiliary room

10.11 Fire Extinguishers

The fire extinguishers shall be 4kg in the

operator’s cab and the other total 8kg or more in

the other cabs. The arrangement can be changed

as requirement of user.

10.12 Refrigerator

The locomotive will be equipped with two (2) 30 L

volume refrigerators to store the foods for drivers

during summer.

10.13 Rearview function

The locomotive will supply the rearview function. Such as the rearview mirror...

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10.14 Foldable seat

Beside the seat for the driver and his assistant,

the locomotive also supply two folder seats for the

other people if he need seat in the driving cab

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11 PAINTING

11.1 Surface treatment

According to UIC842-3 standard including the metallic surface and non-metallic

materials surface.

11.2 Variety and color of the paint

The variety and color of the paint of each part are as follows:

No. Variety of the paint Color Remarks

1 H06－1 Epoxy primer Iron read

Inner car body

and the

components

2 Various of alkyd finish Sea grey, silver

grey,black grey,red,white

Inner car body

3 SG64 Bi-component

epoxy primer

RAL3012 Exterior surface

of the car body,

bogie and

components

4 Unsaturated polyester

paint filler

542 Exterior surface

of the car body

5 Various of

polyurethane finish

Black grey, white, green Exterior surface

of the car body

6 Alkyd aluminum paint Silver powder Aluminous

components

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Note:The colour of the paint execute the international (Europe) colour standard.

Thereinto:

black grey: RAL 7016;

white: RAL 9018;

green: RAL 6024;

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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.

The International Union of Railways Standards (UIC)

International Organization for Standardization (ISO)

International Electro. Technical Commission Standard (IEC)

Standard of MOR of the People’s Republic of China (TB)

National Standard of the People’s Republic of China (GB)

German Standards of Material and Specification (DIN)

12.2 Standard list

No. Code Description

1 UIC651 Layout of driver cab

2 UIC641 Dead man device

3 UIC812-3 Locomotive wheels

4 UIC506 -GC Locomotive guage

5 UIC842-3 Method for testing paint product

6 UIC 822 Spring specification

7 UIC534 Signal lamp

8 IEC61133 Rolling stock testing procedure

9 DIN6700-SGK2.3 Welding

10 EN15528:2008 Load limits

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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 1333.1—2002 eqv.IEC 60077-1—1999 Electric equipment for

rolling stock Part1：Generral service conditions

and general rules

17 TB/T 1333.2—2002 eqv.IEC 60077-2--1999 Electric equipment for

rolling stock Part2：Electrotechnical components

General rules

18 TB/T 1333.3—2002 eqv.IEC 60077-3--2001 Electric equipment for

rolling stock Part3：Electrotechnical components

Rules for DC circuit-breakers

19 TB/T 3034-2002 eqv EN50121-3-2—2000 EMC tests and limits for

rolling stock apparatus

20 TB/T 3021－2001 eqV IEC 60571：1998 Electronic apparatus for

railways

21 UIC615-4 OR Bogie frame structure strength tests

22 UIC566 Strength of the locomotive body

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13 VENDORS’ LIST OF MAIN WEARABLE PARTS

No. Item Supplier

Diesel Engine

1 Fuel injector module Beijing Nankou

Zhejiang Liwei

2 Fuel filter element Xingxiang

3 Turbocharger filter element Xingxiang

Electric motor and electric system

1 Main alternator carbon brush

CSR Chengdu Locomotive&Rolling

Stock Co.,Ltd

CNR Yongji Electric Machine

Factory

2 Traction motor carbon brush


Stock Co.,Ltd


Factory

4 Start motor carbon brush

CSR Xiangfan traction motor

Co.,Ltd

CSR Zhuzhou Electric Machine

Factory

5 Auxiliary motor carbon brush


Stock Co.,Ltd


Factory

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6 Air compressor motor carbon

brush Xian Motor Factory

7 Headlight bulb Hebei Handan

8 Mark light bulb Changzhou Vehicle Auxiliary

Equipment Factory

9 Illumination bulb Wuxi Linge

10 Various Contactor terminals Xi’an Schaltbau Electric Co.,Ltd

Bogie

1 Brake shoe Beijing Huaxia

2 Dry type lubrication carbon stick Jinan Sanhe

Brake

1 Brake hose Tianjin Rubber Pieces Factory

2 Air compressor air filter element

Shijiazhuang Jiaxiang Precision

Machninery Co., Ltd

Beijing Nankou

3 Wiper blade Beijing Guotong

Auxiliary system

1 Lubrication oil filter element CSR Qishuyan locomotive Co.,Ltd

2 Fuel first stage filter element CSR Qishuyan locomotive Co.,Ltd

3 Paper air filter Shanghai Air Filter Factory

4 Various rubber pieces Hebei Guan

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14 MAJOR SUPPLIER INFORMATION

No Item Supplier

Diesel Engine

1 Diesel engine general

assembly CSR Qishuyan locomotive Co.,Ltd

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

9 General assembly of

cylinder cover CSR Qishuyan locomotive Co.,Ltd

10 General assembly of

cylinder liner CSR Qishuyan locomotive Co.,Ltd

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

1 Main alternator CSR Chengdu Locomotive&Rolling Stock Co.,Ltd

CNR Yongji Electric Machine Factory

2 Traction motor CSR Chengdu Locomotive&Rolling Stock Co.,Ltd


3 Blower motor CNR Yongji Electric Machine Factory

CSR Chengdu Locomotive & Rolling Stock Co.,Ltd

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CSR Zhuzhou Electric Machine Factory

4 Start motor CSR Xiangfan traction motor Co.,Ltd


5 Auxiliary motor CSR Chengdu Locomotive&Rolling Stock Co.,Ltd


6 Cooling fan motor

CSR Chengdu Locomotive&Rolling Stock Co.,Ltd



7 Electric cabinet Xi’an Railway Signal Factory


8 Main silicon rectifier CSR Zuzhou

Xian Ketian

9 Console Xi’an Railway Signal Factory


10 Major electric

components Xi’an Schaltbau Electric Co.,Ltd

11 Microcomputer system Zhuzhou CSR Times Electric Co.,Ltd

12 Dynamic braking device

Changzhou Xieshun Motor Trolley Compoonents

Co.,Ltd

Xi’an Railway Signal Factory

13 Battery Xingxiang Taihang

Shiquan Changhong

Bogie

1 Bogie assembly CSR Qishuyan locomotive Co.,Ltd

2 Bogie frame CSR Qishuyan locomotive Co.,Ltd

3 Damper Sachs Automotive Components & Systems Shanghai

Co.,LTD.

4 Wheel set CSR Qishuyan locomotive Co.,Ltd

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5 Transmission gear CSR Qishuyan locomotive ＆ rolling stock

technology research institute LTD

6 General assembly of axle

box

CSR Qishuyan locomotive Co.,Ltd

7 Foundation brake rigging CSR Qishuyan locomotive Co.,Ltd.

Brake

1 JZ-7 air brake

Tianjin Railway Vehicle Transportation Equipment

Co. Ltd.

Shenyang Locomotive & Rolling Stock Brake

Equipment Co., Ltd

2 Air compressor Shijiazhuang Jiaxiang Precision Machinery Co., Ltd

Beijing Nankou Company

3 Air dryer

Qindao Zhongjian Comprehensive Technology

Research Institute Co., Ltd

4 Main reservoir CSR Qishuyan locomotive Co.,Ltd

Car body

1 Car body CSR Qishuyan locomotive Co.,Ltd

2 Coupler LAF (France)

Or Iran local product

3 Driver chair Chendu Tianlong Transportation Equipment Co., Ltd

4 Air conditioning Laiwu sanhe science and technology Co.,Ltd

Changzhou ketai electron co., Ltd

5 Refrigerator Hangzhou Railway Motors Factory

Laiwu sanhe science and technology Co.,Ltd

Auxiliary system

Page 138


1 Cooling system CSR Qishuyan locomotive Co.,Ltd

2 Radiator Dalian tongtie thermodynamics Co.,Ltd

Wuxi Dongjiang

3 blower Hangzhou Railway Motors Factory

Changzhou Wuyi

4 Cooling Fan

Weihai Creditfan Ventilator Co.,Ltd

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

7 Lubrication oil heat

exchanger CSR Qishuyan locomotive Co.,Ltd

Documents

Spek Tek Lokomotif Iran