dl gen i update july 2012. dl gen i - summary key business requirements - recap delivery timeframe...

DL Gen I UpdateJuly 2012

DL Gen I - SummaryKey Business Requirements - recap

• Delivery Timeframe » Urgent. Increase in Freight & Passenger1 demand

• Supplier » Existing supplier, capability, specification, warranty.

• Two cabs » 2-for-1 replacement, reduces need to turn (but option for “recovery”)

• Homogenous » Reduce range of “train-specific” locos, maintenance, inventory

• Horsepower » 2700kW for timetable performance (especially 2-for-1).

• Weight » 108t (maximise to 18t axle load limit).

• Engine » MTU 20V4000R43, Electronic Fuel Injection, EU Stage IIIA emissions.

• Pricing » Competitive pricing to match specification

• Reliability » High reliability (but this has not been achieved yet).

Key Stats (as at 13 July 2012)

• Kilometres » 1.9 Million km

• Freight Trips » 14,800

1 DFT’s for ARTA

Program Period » December 2011 – May 2012

Rectification Items » Covered under warranty.

• Control System (DLoco) » Loss of amps/loss of power/screen freezes.» Control system card upgrade (MCU, ACU).» Control system software upgrade.

• Traction Motor (Yongji) » SKF bearing failure (rivets loosened, leading to failure).» Fleet-wide replacement program (replaced with same bearing).

• Water pipes (MTU) » Cracked pipes (water leaks).» Turbo vent pipes modified.

• Exciter Base (DLoco) » Cracking, causing excess vibration.» Re-welded exciter.

• Vibration (MTU/Yongji) » Axial vibration on alternator end-plate, resulting in excessive brush wear.» 3 DL’s with very short brush life (9089, 9170 & 9193).» Engine-Alternator realigned.» Alternator Brush Holder improved across fleet.» Further investigations.

Fleet Issues – 1st Rectification Program

Items – cont’d• Compressor aux (DLoco) » Shutting down

» Regulator change, inductor change, control system changes.

• Silencer (Dloco’s sub-supplier) » Cracking, sets off fire alarm.» 20 silencers remanufacture (& rejected). » Sub-supplier refused to rectify again under warranty.» New supplier sourced and 21 silencers manufactured.

• Basin Pump (DLoco’s sub-supplier) » Burns out when left on.» Replaced with continuous duty pump.

• Adhesion (KR/DLoco) » Configure to NZ conditions (normal requirement for new loco) » Performance across a range of loads, track, climate, driving styles.

» Contributed to the required control system upgrade.

• DL9089 (DLoco) » Alternator vibration (very short brush life)» Waiting spare parts.» Due for release – end July.

• Other » TC radio (Tait)» Portable radio (Motorola)» Headstock cocks (Wellington).

Fleet Issues – 1st Rectification Program – cont’d

Program Period » June 2012 – August 2012

Items » Covered under warranty.

• Control System (DLoco) » Various faults.» ACU card upgrade (factory modified).» Control system software upgrade & rewiring.

• Traction Motor (Yongji) » Repeat SKF bearing failure.» Fleet-wide replacement program (upgraded NU326 bearing).

• Water pipes (MTU) » Cracked pipes, results in water leaks.» MTU coolant pipes modified.

• Exciter Base (DLoco) » Exciter based failed again – original repairs inadequate.» Enhanced support beam being fitted & improved security.

• Vibration (MTU/Alt) » Axial vibration on alternator end-plate.» Some improvement, but investigations continuing.

• Silencer (Dloco’ sub-supplier) » Cracking, sets off fire alarm.» New silencers are being installed.

• “MDBF” » Various.» MDBF failures review.» Rectifications applied as necessary.

Fleet Issues – 2nd Rectification Program

Mon Tue Wed Thu Fri Sat Mon Tue Wed

Exciter Base WeldingTraction Motor BearingExciter Base Welding

Traction Motor Bearing

Exciter AlignmentSilencer InstallMTU Pipe mod


Exciter Base WeldingTraction Motor BearingExciter Base Welding

Traction Motor BearingExciter Base Welding

Traction Motor BearingExciter Base Welding

Traction Motor Bearing

ACU installEng-Alt alignment check

“MDBF” rectifications















Station 1 (3 days)

Station 2 (3 days)

Station 3 (3-7 days)

3 Rectification Stations - 3-7 days per station

10 Week Rectification Plan

#Loco

NumberCurrent MDBF

Alt-Eng Vib

Reading

Exci

ter,

Tra

ction

Mot

or w

eldi

ng

Trac

tion

Mot

or b

eari

ng re

plac

emen

t

Exci

ter a

lignm

ent,

Sile

ncer

inst

alla

tion

, G

earb

ox s

ervi

cing

, Soft

war

e up

adat

es,

Inve

rter

cha

nge,

MTU

Elb

ow

Vib

rati

on &

Gea

rbox

che

ck

ACU

Inst

alla

tion

Fan

blad

e w

eldi

ng

1-Jun 11-Jun 12-Jun 18-Jun 19-Jun 25-Jun 26-Jun 30-Jun 1-Jul 7-Jul 8-Jul 14-Jul 15-Jul 21-Jul 22-Jul 31-Jul 1-Aug 11-Aug 12-Aug 18-Aug 19-Aug 25-Aug 26-Aug 31-Aug

1 DL9008 19,484 32 6-Jun 14-Jun 22-Jun NA

2 DL9158 44,580 50 11-Jun 20-Jun 3-Jul

3 DL9066 8,945 14-Jun 23-Jun 3-Jul

4 DL9020 66,558 33 18-Jun 27-Jun 6-Jul

5 DL9204 4,547 34 21-Jun 6-Jul 9-Jul NA

6 DL9089 - 40 23-Jun 11-Jul NA

7 DL9037 2,946 27-Jun 11-Jul 14-Jul

8 DL9135 41,494 30-Jun NA

9 DL9112 6,558 4-Jul 13-Jul 21-Jul NA

10 DL9193 9,705 23 7-Jul 18-Jul 25-Jul

11 DL9043 5,790 11-Jul 28-Jul NA

12 DL9129 7,929 38 14-Jul 1-Aug

13 DL9106 12,289 18-Jul 4-Aug NA

14 DL9141 18,796 21-Jul 8-Aug NA

15 DL9014 38,998 32 25-Jul 11-Aug NA

16 DL9164 23,398 28-Jul 15-Aug

17 DL9187 22,540 29 1-Aug 18-Aug

18 DL9095 57,552 29 4-Aug 22-Aug

19 DL9170 5,249 26 8-Aug 25-Aug NA

20 DL9072 23,164 28 11-Aug 29-Aug NA

(Pass out date) (Complete) (Reschedule prior to 1 Sept) GEN I RECTIFICATION PROGRESS Legend:

dd-mm

June Shop Dates July Shop Dates August Shop Dates

Alternator Change - Date to be advised

Individual DL MDBF Performance

Fleet Utilisation & Performance

• Alternator Vibration » Axial Vibration.» Identification of Cause.» Investigation ongoing.

• Alternator Fan » Cracks and failure of Fan Blade on 9135.» Interim fix applied.» Possible replacement of all fans?» Engine-Alternator removal and realignment?» Solution being developed by Yongji.

• Drive-train gearbox » Overheating, leading to breather pipe failure» Incorrect oil used (on advise from Mobil).

» Breather pipe hose modification and oil change.

Main Outstanding Issues

DL Gen II UpdateJuly 2012

DL Generation II - Status• Contract in place » 20 DL’s.

» Pre-dominantly the same loco.» Required by 2013 peak season.

• Gen II Prototype » Assembly completed.» Functional testing completed.» Scheduled to run on rolling-road for 3 weeks.

• Main Production » Has been “paused”.» Enables Gen I mods to be applied prior to Production.» Potential re-start of 1st October 2012.

• » Expect delivery mid-2013.

DL Generation II - Changes

• Gen I Rectifications » Gen I “learnings” applied to Gen II.

• Compressor » Atlas Copco, France (was Knorr VV450 , Germany).

• Front Window » Lowered by 60mm.

• Drivers Footstep » Re-design (switch position, adjustment range).

• Console Desk (right hand side) » Re-design (improved access).

• Head light switch » Re-arrangement proposed.

• Emergency egress » Above-window hand-grab, modified first foot-step.

IAB UpdateJuly 2012

IAB - SummaryKey Business Requirements - recap

• Delivery Timeframe » Urgent. Increase in Freight demand

Key Stats (as at 17 July 2012)• Configurations » 439 IAB’s

» 59 ZXT’s» 2 ZXM’s

• Kilometres » 26.4 Million kms

• Trips » 81,000 trips

• Camber » Difficulty with loading some empty 40’ containers. » Too much underframe camber.

» Supplier developing proposal for evaluation.

• Wheel-skids » Running with hand-brakes on.» Number of incidences reducing.

• Brake system performance » Compliance achieved.» Required modifications as part of commissioning (brake block).» Further modification are being considered.

• Dynamic ride » Compliance achieved.» Required modifications as part of commissioning (friction wedge).

• Brake Beam » Damaged during lift-offs.» Brake lever setup modification changed to prevent damage.

Key Issues

dl gen i update july 2012. dl gen i - summary key business requirements - recap delivery timeframe...

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