JW-4G Catenary Cable Maintenance Vehicle is mainly used for the installation, maintenance and daily inspection and maintenance of the overhead equipment of the contact system in the high-speed railway; it can also function as traction vehicle to be used in recovery work of contact system by linking with other vehicles. Below is outline drawing of the vehicle (only for your reference). Refer to attached drawing for outline and plan layout (only for your reference).
The vehicle is mainly composed of vehicle body, frame, running gear, lifting and slewing platform, onboard crane, telescopic lifting mast, etc. The lifting and slewing of platform can be controlled at both the upper and lower side of the working platform.
Main technical characteristics:
The power transmission system is featured with advanced technical performance, well-proven matching, reasonable and strong traction capacity, less maintenance and easy repair.
The running gear is built in a reasonable structure and the spring system has been optimum designed with maximum running speed of 120km/h.
JZ-7 automatic brake valve for locomotive is adopted. On the control console, only the handles of automatic brake valve and independent brake valve exposed outside with nice and simple arrangement.
The power transmission system is suspended mounted. The whole vehicle has taken perfect sealing measures with good sound proof and heat-insulated performance.
Connection device is provided between car frame and bogie and between bogie and wheel set, which are not required to bind with locking device when vehicle is hoisted or resuming.
The axle box is set with anti-overturn device which can be used to prevent overturn due to off-line of vehicle.
The outer sheath of vehicle body adopts whole plate stretching technology. The floor is built in multi-layer sealing structure and coated with flame retardant oil resistance plastic flooring. Side window adopts double-layer glass for a perfect sealing of the vehicle.
It has a good anticorrosive performance. The steel structure has been pretreated as surface blasting and plate unrolling leveling, etc. Advanced two components polyurethane paint and advanced cyclic hot stoving finish house are adopted for quality of the painting.
All hydraulic elements adopt famous brand. The hydraulic valves in main circuit and platform circuit are integrated in valve cabinet for convenience of the inspection.
It is set with safety precautions like platform slewing area select function, bypass brake system, hand emergency oil pump, platform hand mechanical slewing, platform gravity drop and rail tong, etc. The safety precautions are sound and complete for a safety operation.
Master parts concerning electrics, hydraulics, power transmission and suspension, etc. will be tested with advanced testing methods before assembled to the vehicle for ensuring their quality and performance.
Most of our products are designed on the basis of the requirements of standardization and modularization. The components have a good commonality for providing an easy maintenance and inspection of the vehicle.
The vehicle body adopts advanced polyurethane paint with better weather resistance and hard film that is featured with acid and alkali resistant, solvent resistant and humidity resistant performance. Vehicle body adopts yellow and white paint and working mechanism adopts yellow paint. The vehicle frame and lower part are painted in dark grey color.
The mark of the vehicle conforms to relevant regulation. The operation and maintenance of the vehicle has been highly marked on relevant parts for easy operation, troubleshooting and maintenance by the driver. Lifting position and mark are available.
The vehicle has been obtained Type Certificate (No.: TXZS0801-00681) and Production License (No.: TXZZ0801-01859) issued by National Railway Bureau.
1.1 Ambient temperature: -25℃～+45℃
1.2 Altitude: ≤3000m
1.3 Maximum super elevation: Meet the requirements of railway line codes; working platform is set with automatic leveling device.
1.4 Relative humidity: Average monthly relative humidity ≤90%; Average daily relative humidity ≤95%
1.5 Maximum wind speed: ≤15m/s
1.6 Working environment: Outdoor work, it can work in area with frequent thunder and should withstand wind, sand, rain and snow, and can used for night work
2.1 Track gauge: 1,435mm
2.2 Wheel diameter 840mm
2.3 Axle arrangement: 2-B
2.4 Axle distance: 2,400mm
2.5 Number of axles: 4 axles
2.6 Load per axle: about 12t
2.7 Center distance of bogie: 9,200mm
2.8 Minimum radius of curvature negotiable:100m (10km/h)
2.9 Maximum running speed: 120km/h（traction load 50t）
2.10 Maximum running speed, when coupled: 120km/h
2.11 Engine power: 353kW(480Ps)
Type WP12.480 electronic fuel injection diesel engine made by WEICHAI is adopted which emission meets national III standard.
Main technical parameter of diesel engine is as follows.
Type | WP12.480 |
Mode | Water-cooled, vertical, in line type, six-cylinder, four-strokes |
Air intake mode | Supercharged, air-air aftercooled |
Total output | air-air aftercooled |
Rated power | 353kW(480Ps) |
Rated rpm | 2100rpm |
Maximum torque | 1970N·m |
Maximum torque rpm | 1200～1500rpm |
Refer to following for outline of the engine.
Profile drawing of Weichai type WP12.480 electronic fuel injection diesel engine
2.12 Exhaust emission standard: National III standard
2.13 Volume of fuel tank: ≥1000L
2.14 Storage battery: 200Ah×4 pieces (each piece is composed of six 2V batteries which are connected in series. The voltage is DC12V and capacity is 200Ah. Two pieces connected in series as a group (each group integrated in a box). Two groups are connected in parallel for power supply).
2.15 Traction mode: Hydrodynamic drive (including coasting self-lubricating system)
German VOITH made T211 horizontal hydraulic transmission is installed. The transmission is built in doule cyclic round structure with hydraulic gearshift to offer high driving efficiency with whole speed range, fully satisfying the vehicle traction performance requirement. The transmission is designed with trailing lubrication system, therefore no need to remove propeller shaft even when long distance trailing operation with power off.
Integrated cooling device concentrates radiation from turbocharged air, coolant, driving oil and hydraulic oil, simplified structure and saved suspension space underneath, making it easy for maintenance.
2.16 Mode of braking: Air braking and hand braking
2.17 Air brake: JZ-7 air brake
2.18 Brake riggings: can realize brake block slack adjustment
2.19 Air compressor output: 1.08m³/min (Shenzhen Jucai)
2.20 Total Air Reservoir Volume: 500 L
2.21 Coupler and draft gear: 13B coupler and ST draft gear
2.22 Height from car coupler center to track surface: 880mm±10mm
2.23 Weight in working order: About 47t
2.24 Single vehicle braking distance: ≤400m (straight line，80km/h initial speed)
≤800m (straight line, 120km/h initial speed)
2.25 Gradeability: 33‰
2.26 Overall size: 15930mm×3118mm×4740mm
2.27 Traction dynamic table
Running speed(km/h) | Traction force at wheel rim(kN) | Traction tonnage on various slopes (t) | |||||
0‰ | 6‰ | 12‰ | 18‰ | 24‰ | 30‰ | ||
0 | 51.3 | 1050 | 360 | 220 | 150 | 100 | 75 |
10 | 42.6 | 1050 | 360 | 220 | 140 | 90 | 60 |
20 | 34.3 | 1050 | 300 | 160 | 90 | 60 | 35 |
30 | 27.6 | 1050 | 250 | 110 | 60 | 35 | |
40 | 22.3 | 950 | 180 | 80 | 40 | ||
50 | 18.3 | 700 | 130 | 50 | |||
60 | 15.2 | 500 | 90 | 30 | |||
70 | 12.8 | 350 | 60 | ||||
80 | 10.5 | 240 | 30 | ||||
90 | 10.4 | 200 | 25 | ||||
100 | 9.9 | 150 | |||||
110 | 9.3 | 100 | |||||
120 | 8.7 | 60 | |||||
Clearance: Meet relevant requirement of GB146.1-1983.
3.1
Operate on both ends, with the driver position on the left and the co-driver position on the right.
3.2
The back end of cab has door accessing to work area.
3.3
The cab inside is set with two berths which can ensure the seating for 15 person (including driver seat). The storage box is set under the berth.
3.4
Safety glass is installed on windows at front and back of cab and doors and windows on the right and left of cab so that driver can watch without obstacles during operation, and windscreen is equipped with sun shading roller shutter.
3.5
Windows at front and back of cab are set with water spray type window wiper.
3.6
The decorative sheet of cab is made of noncombustible glass fiber reinforced plastics and filled in heat insulation material in walls. The vehicle inside adopts double plywood suspended ceiling for air-conditioned passenger train. The vehicle door adopts labyrinth seal. The floor is designed in multilayer structure and painted with acoustic absorption damping adhesive. The floor of cab is applied with flame retardant oil resistance plastic flooring. Movable floor for inspection is available. The noise in cab after all doors and windows closed is no greater than 85dB.he wiring and air pipeline entering into the cab is proper sealed.
3.7
The electric fan is installed above the driver’s seat. One set of 3P ceiling-mounted air conditioner is available in the cab. The temperature inside in winter will not be less than 16℃ while that in summer will not be more than 27℃.
3.8
When ceiling lamp in cab are off under sunlight and at night, the display instruments and indicator lamp in cab can be observed at the distance of 500mm.
3.9
The cab is set with LED ceiling light which illumination meets the requirements of maintenance and driver’s operation.
3.10
The vehicle is set with two berths. The tool box and material box are set under the berth. The workbench is available. One set of maintenance tool is available.
3.11
The cab is set with two fire extinguishers for the convenience of use.
3.12
The vehicle is set with two berths.
3.13
Stainless steel tube is adopted for air pipe line. Oil-water separator and air drier are available to ensure reliable work of valves.
3.14
Headlight, lower headlight and signal light are provided on both ends of vehicle. Instrument light is provided on console, and illuminating lamp is provided in cab (adopting cold light source), and the above lighting meets TB 2180-2006 standard.
3.15
The vehicle is set with one set of diesel generator set and power distribution unit. The rated output of generator set is not less than 10kVA (8kW), voltage AC220V (single phase)/ 380V (three-phase). Power receptacles are provided, one is 380V 2kW and the other two are 220V 1kW (one receptacle led out is provided on maintenance platform and with outdoor waterproof function), the both ends and both sides of the vehicle are provided with external power receptacle.
3.16
Advanced welding technology and rust prevention treatment technology are adopted for main car frame.
3.17
The vehicle adopts horizontal type hydrodynamic transmission box. This transmission box is built in dual cycle circular structure with hydraulic shifting. The transmission box has been successfully used in railway operation without friction plate and other quick-wear parts. It has a long open box overhaul life.
3.18
The vehicle is designed and manufactured based on the requirements of standardization, serialization, modularization and informatization, adopting digital control system and modular function arrangement. It can be combined according to user’s demands.
3.19
The standard LM-type tread and integral rolled steel wheels are adopted. Car axle material conforms to standard requirements. Wheel and axles adopt oil feeding press assembled and the assembly technology complies with relevant stipulations.
3.20
Two suspension vibration attenuation is adopted, primary suspension is composed of metal helical spring and vertical hydraulic damper; secondary suspension is composed of side bearing of rubber metal pad and horizontal hydraulic damper.
Hydraulic lifting and rotation operating platform, equipped with automatic plumbing device, meets the following technical parameters:
4.1 Dimensions of platform (length× width): 5500mm×1750mm
4.2 Maximum lifting height (from platform floor to track surface): ≥6400mm
4.3 Operating radius: 4,500mm
4.4 Maximum load bearing capacity of rotation center of platform: 1,000kg
4.5 Maximum load bearing capacity at the farthest end of platform: 300kg
4.6 Rotation angle of platform: ±120°
4.7 Height of railing: 1,100mm (foldable)
4.8 The lifting and rotation of operating platform can be operated by personnel on the platform or personnel under the platform, interlocking and conversion arrangement are available. Lifting and rotation speed conforms to codes.
4.9 Seven LED lamps are set on the platform, adopting cold light source and two anti-shock lamps (spotlights) are provided which illumination satisfies the requirements of operating during the night.
4.10 The vehicle is set with one set of wired communication equipment and two sets of hand-held wireless walkie-talkie.
4.13 The vehicle is set with one set of grounding device.
The vehicle is set with onboard fully-hydraulic arm crane that is composed of winch, luffing system, arm telescoping mechanism and slewing mechanism, etc., with flexible operation, good inching movement and reliable working, mainly used to lift and transport various tools and equipment, etc. to working platform. Refer to following for its technical parameters.
5.1 Mode: Fully-hydraulic telescopic arm
5.2 Maximum lifting capacity moment: 4t·m
5.3 Maximum elevating capacity: 2,000kg
5.4 Maximum lifting height (from track surface): 10,200mm
5.5 Maximum working radius: 8,200mm
5.6 Elevating capacity with maximum working radius: 250kg
5.7 Maximum elevation of cargo boom: 76±1°
5.8 Range of rotation: 360° full rotation
Telescopic lifting mast is used in catenary wire installation operation.
Telescopic lifting mast is built in box structure with single-stage double acting cylinder. The entire device consists of supporting arm, jacking cylinder, hydraulic motor, retarder box, winch and other components. The main technical parameters are as follows:
Maximum height of the bracing arm (above track surface):7100mm
Maximum lifting tension: 30kN
7.1 Waterproof limit switch is provided for platform elevating and slewing.
7.2 Emergency switch is provided on control device, so that main oil circuit can be cut out promptly and stop the movement of platform in case the lifting and slewing of platform is out of control.
7.3 Emergency hand pump is provided so that working mechanism can be promptly recovered to transportation position in case of failure of main hydraulic oil circuit.
7.4 Mechanical manual operated platform slewing device is provided so that the platform can be reset manually within 5 minutes in case of failure of hydraulic system of platform slewing mechanism.
7.5 Cut off valve is provided in lifting hydraulic circuit of stand column, in case of failure of hydraulic system of column, the column can drop by its own weight to return to its original location by opening cut off valve.
7.6 Solenoid valve is equipped with manual control, and it can be controlled manually in case of failure of electronic control part.
7.7 Four sets of rail tong is provided which can be used when wind speed is more than 15m/s.
7.8 Reliable grounding measure is available for vehicles to guarantee safety of equipment and personnel.
7.9 Bypass braking system is provided so that emergency braking can be carried out on working platform.
7.10 Electrical control system have functions of selecting operating platform rotation area, with left and right or both side options to ensure safety of multiple track section.
7.11 Front and back control board have relay interlocking control to avoid malfunction.
7.12 Open circuit indication is set to find out fault rapidly.
7.13 Various electrical equipment used outdoor reaches corresponding grade of protection.
7.14 Axle head is set with grounding protection device; axle box body is provided with anti-overturn device to effectively prevent overturn accident due to off-line of vehicle.
7.15 Safe connection device is provided between car frame and truck frame and between truck frame and axle box wheel, which are not required to bind when vehicles are hoisted or resuming.
1. Hydraulic rerailer: One set.
2. The vehicle is set with four sets of rail clamping device. When the wind speed exceeds 15m/s, the rail clamping devices can be used. Also, the hydraulic stabilizer can be used in the operation.
3. The vehicle is set with four pairs of brake shoes.
1. The vehicle is provided along with Onboard consumable parts list of JW-4G Catenary Cable Maintenance Vehicle, Onboard tools list of JW-4G Catenary Cable Maintenance Vehicle, Onboard living parts list of JW-4G Catenary Cable Maintenance Vehicle, and Onboard traveling parts list of JW-4G Catenary Cable Maintenance Vehicle, included in basic quotation for evaluation.
1. Standard for equipment manufacturing and acceptance: our company will strictly carryout design, fabrication and acceptance in accordance with GB/T 19001-ISO 9001 Quality Management Systems – Requirements and GB/T 10082-2010 Technical Requirements of Heavy Duty Railway Motor Trolley. Original material of the car and suppliers of components will be examined and certificated for sub-contractor qualification. All original materials and components will be inspected strictly for purchasing.
2. Our company will provide all product supply lists to the Customer as the basis for the Customer’s inspection and acceptance.
3. Test standard and method will be provided by our company and confirmed by the Customer.
4. Carry out comprehensive tests concerning running, brake, hydraulic lifting slewing platform performance, emergency reset of the working device, car body rain and noise and will provide complete test reports.
We will provide the following for each machine:
Service and maintenance instructions for Catenary Cable Maintenance Vehicle: 3 sets
Service and maintenance instructions and parts catalogue for the engine: 3 sets
Vehicle certificate: 1 set
Documents list: 3 sets
Documents for trial run: 3 sets
List of spare parts and special tools with vehicle: 3 sets
Including: Onboard consumable parts list of JW-4G Catenary Cable Maintenance Vehicle;
Onboard tools list of JW-4G Catenary Cable Maintenance Vehicle;
Onboard living parts list of JW-4G Catenary Cable Maintenance Vehicle;
Onboard traveling parts list of JW-4G Catenary Cable Maintenance Vehicle.
Axle detection report: 2 sets
The design, manufacture and use of vehicle will refer to relevant design codes of diesel rolling stock and vehicle, and it will also meet standards below:
GB146.1 Rolling Stock Gauge for Standard Gauge Railways.
TB/T 2180-2006 Technical Specification for Electrified Catenary Inspection & Maintenance Railway Working Car.
TB/T 2962-1999 Technical Requirements for Diesel Locomotive, Track Car and Diesel Motor Train Unit Control Device.
Attached drawing: Profile and plain layout drawing of JW-4G Catenary Cable Maintenance Vehicle (only for your reference)
