DL Gen I Update July 2012 DL Gen

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. • Two cabs » 2 -for-1 replacement, reduces need to turn (but option for “recovery”) • Homogenous » Reduce range of “train-specific” locos, maintenance, inventory • Horsepower » 2700 k. W for timetable performance (especially 2 -for-1). • Weight » 108 t (maximise to 18 t axle load limit). • Engine » MTU 20 V 4000 R 43, 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

Fleet Issues – 1 st Rectification 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 – 1 st 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. • DL 9089 (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 – 2 nd Rectification 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 NU 326 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.

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

10 Week Rectification Plan

Individual DL MDBF Performance

Fleet Utilisation & Performance

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.

DL Gen II Update July 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 1 st 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 VV 450 , Germany). • Front Window » Lowered by 60 mm. • 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 Update July 2012

IAB - Summary Key Business Requirements - recap • Delivery Timeframe Key Stats (as at 17 July 2012) • Configurations » Urgent. Increase in Freight demand » 439 IAB’s » 59 ZXT’s » 2 ZXM’s • Kilometres » 26. 4 Million kms • Trips » 81, 000 trips

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 • Brake Beam » Compliance achieved. » Required modifications as part of commissioning (friction wedge). » Damaged during lift-offs. » Brake lever setup modification changed to prevent damage.