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DL Gen I Update July 2012

DL Gen I Update July 2012. DL Gen I - Summary. Key Business Requirements - recap Delivery Timeframe » Urgent. Increase in Freight & Passenger 1 demand Supplier » Existing supplier, capability, specification, warranty .

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DL Gen I Update July 2012

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  1. DL Gen I UpdateJuly 2012

  2. DL Gen I - Summary • Key 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

  3. Fleet Issues – 1st Rectification Program • 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.

  4. Fleet Issues – 1st Rectification Program – cont’d • 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).

  5. Fleet Issues – 2nd Rectification Program • 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.

  6. 3 Rectification Stations - 3-7 days per station Station 1 (3 days) Exciter Base Welding Traction Motor Bearing Exciter Base Welding Traction Motor Bearing Exciter Base Welding Traction Motor Bearing Station 2 (3 days) Exciter Alignment Silencer Install MTU Pipe mod Exciter Alignment Silencer Install MTU Pipe mod Exciter Alignment Silencer Install MTU Pipe mod Station 3 (3-7 days) ACU install Eng-Alt alignment check “MDBF” rectifications ACU install Eng-Alt alignment check “MDBF” rectifications ACU install Eng-Alt alignment check “MDBF” rectifications

  7. 10 Week Rectification Plan

  8. Individual DL MDBF Performance

  9. Fleet Utilisation & Performance

  10. Main Outstanding Issues • 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.

  11. DL Gen II UpdateJuly 2012

  12. 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.

  13. 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.

  14. IAB UpdateJuly 2012

  15. IAB - Summary • Key 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

  16. Key Issues • 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.

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