Israel Railways Ltd.

Rolling Stock Division

Technical Characterization No.

M-01-509
for the supply of

UTEX turbochargers for

EMD's diesel engine type

12N-710G3B-T3

(JT42BW Locomotives)

Professional committee Rev

Participant Sign Date

Maxim Dukhovny 13.11.2022

Tal Almoznino 13.11.22 00

Igor Kisilisa 13.11.2022

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Rolling Stock Division

Table of contents

1. Introduction ……………………………………………….....……...……...3

2. Technical Requirements ………..……………………………………….. 3

3. Testing Requirements ………………..……………….………….…..….. 4

4. Pilot Tests …………………………………………………………………..5

5. Turbocharger Nameplate …………………………….….……………..... 6

6. Required Documentation ……………………………..….……….……... 7

7. Environmental Conditions ………………………… …….…………….... 7

8. Warranty ………………….………………………………………………... 8

9. Logistical Requirements……………………………………...………….…8

10. Training….. ……………………………………………………..………...8

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1. Introduction
ISR is intended to purchase a refurbished turbochargers for its fleet of JT42BW locomotives, made
by Alstom company.
From now on, fully refurbished according to manufacturer spec will be refer as "UTEX."
This turbochargers is intended to be installed on an EMD two stroke diesel engine model
12N-710G3B-T3. This engine have been modified to fully comply with Tier 3 exhaust emission,
according to EPA regulations .
This engine is a refurbished one, with an official EMD p/n of 40309616.
Here below will be a sum of the technical characterization required for the transport, supply,
warranty, instructions, providing tech data sheets, providing maintenance plan and maintenance
instructions and providing certificates of conformity for the UTEX turbochargers.

2. Technical Requirements

1.1 The supplier must make a preliminary study of the relevant constraints for the JT42BW
locomotive and for the EMD two stroke diesel engine, in order that the fitment of the supplied
turbine will be the same as of the original EMD turbine.
1.2 The supplied turbocharger must be fully configured for installation and operation on EMD's
engine 40309616 (UTex), and fully compatible for operating JT42BW Locomotive.
1.3 The Turbocharger performances must meet the EMD's engine 12N-710G3B-T3 requirements for
all operation modes, and must be compatible to EMD's Turbocharger P/N: 40111761
performances and implementations.
1.4 The turbocharger must meet the assembly method and all of the geometric and environment
requirement to be adapted to the locomotive and EMD's engine
1.5 The supplier must provide EPA (U.S. Environmental Protection Agency) formal confirmation
that assembling the turbocharger on EMD's engine part no. 40309616 meets the required and
original emission level Tier 3.
1.6 The supplier must ensure that the turbocharger configuration is completely meet with ISR
locomotives configuration.
1.7 General technical details as reference for the turbo charger:

ISR Loco # Engine type EMD's p.n. for

Engine
731-778 12N-710G3B-T3 40309616

1.8 The provided turbo charger must ensure fully appropriation for engine performance, including
the lube oil, cooling water and air intake/exhaust systems including pumps and filters, and all
necessary protective devices.

1.9 The provided turbocharger must keep the same geometrical dimensions of the original assembly,
and ensure the same connection and assembly to the engine.

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1.10 The provided turbo charger must avoid compromising the engine performances and will keep on
the same original maintenance plan for the same engine type.

1.11 The supplier responsible for studying and verifying all of the required operation and technical
details of the engine and the locomotive, and to provide an appropriate turbocharger as described
in this document.

1.12 The refurbish procedure should use an original EMD parts, or equal in quality other
manufacturer replacement parts only.

1.13 The refurbish procedure should ensure the use of suitable mechanical gear drive assemblies. no
unhardened gear drive will be assembled mixed, with a hardened one.

1.14 The supplier must ensure a full availability of spare parts for period of at least 10 years. in any
case of an obsolete item, the supplier will be responsible to provide a replacement, with an equal
in quality and in price item to the obsolete one.

3. Testing requirements

3.1. The supplied turbo must supplied after a full break-in run procedure, and is ready to be
installed on the engine.
3.2. The supplier must provide testing reports under full loads with accordance to the required
engine's performance.
3.3. The performance testing procedure must include, among the others, the following conditions:
3.3.1. vibrations monitoring: the vibrations needs to be diagnosed and an approval must
be presented
3.3.2. turbine temperatures should be monitored during the run and a full data spec
should be attached to each turbo supplied.
3.3.3. oil pressures should be monitored and be posted on the final report.
3.3.4. amount of vented oil should be monitored and be included in the final report
3.3.5. Turbo rundown time should be documented.

3.4. A full report of all of the monitored parameters, during the tests, will be compared and
presented next to the allowed specs as of directed by EMD, relevant for this type of
turbochargers.
A set of documents for test data & readings should be supplied with each turbocharger
including:

3.4.1. Technical parameters that must be included, among the previous requested, during
the testing (run-in), procedure:

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3.4.1.1. Rotor speed.

3.4.1.2. Compressor inlet and outlet temperatures.
3.4.1.3. Turbine inlet and outlet temperatures.
3.4.2. Oil System Check:
3.4.2.1. Oil flow rate.
3.4.2.2. Oil supply pressure.
3.4.2.3. Oil compressor bearing pressure.
3.4.2.4. Oil In temperature.
3.4.2.5. Oil Out temperature.
3.4.2.6. Oil Tank/Vat temperature.
3.4.3. Vibrations Systems Check.
3.5. During assembly all readings and serial numbers will be recorded and furnished to Israel
Railways.
3.6. Emission level testing report with EPA formal confirmation document.
3.7. During assembly, the compressor rotor clearances to the duct, such as other relevant
measurements should be reported and attached to the final report.

4. Pilot tests.
4.1. The pilot tests (25K) will be performed after the installation of a prototype is completed.
4.2. The pilot will include 3 stages:
4.2.1. Receiving of prototype and incoming inspection.
4.2.1.1. Receiving all required technical data, in accordance with the specification.
4.2.1.2. Checking compliance with the specification requirements.
4.2.1.3. Initial installation of a turbocharger in a locomotive and verification of a complete
and proper interface.
4.2.1.4. Inspection of the interface using the locomotive computer and confirming the
correct data transfer.
4.2.1.5. Starting the turbocharger and performing a series of initial load tests and test
drives.
4.2.1.6. Checking the absence of smoke, unusual noises or any other abnormality.
4.2.2. Tests and inspections during the pilot period.
4.2.2.1. Weekly inspection by ISR technical team.
4.2.2.2. Inspection to confirm the absence of any abnormalities, such as smoke, unusual
noise, loosening of screws, oil leakages, etc.
4.2.2.3. General visual inspections.

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4.2.2.4. Interface testing using the locomotive computer and confirming the correct data
transfer.
4.2.3. Tests after the end of the pilot period.
4.2.3.1. Comprehensive inspection at the end of the pilot for the absence of any defects
and abnormalities.
4.2.3.2. Downloading a data log for the entire pilot period and checking for the absence of
any malfunctions.
4.2.3.3. Receiving all required technical data, in accordance with the specification,
including updates if necessary.

5. Turbocharger Nameplate.

5.1. The structures of the serial number and identification code should be in accordance with the
requirements detailed below.

140 mm

40 mm

Turbocharger Nameplate (for reference only)

5.2. Material: Aluminium, Length: 140 mm, Width: 40mm, Thickness: 2mm.
5.3. All markings should be positively stamped on the appropriate place on the plate.
5.4. General dimensions must be with accordance to the detailed in the figure above
5.5. Notes:
- First two digits in the serial number mean year of manufacture.
- 3rd digit in the serial number means month of production year (A = January, B = February, etc.
The letter "I" is not used, so a December built turbo carries an "M" designation).
- 4th digit in the serial number must be "3" – UTEX turbocharger.

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6. Required Documentation:

6.1. Fully QC reports for the testing requirements as detailed in section 3.

6.2. Quality Certificate confirming compliance with original specifications and performance
(COC).
6.3. Complete documentation for relevant components - COC, COT,COP
6.4. Full maintenance plan and technical instructions
6.5. Storage instructions (Long period and short period).
6.6. Recommended spare parts list.
6.7. Troubleshooting documentation.
6.8. Detailed BOM specify the OEM part numbers.
6.9. Equipment and facilities list that should be used in assembly, maintenance and testing
6.10. Quality control documentation for assembly and maintenance procedure
6.11. CAD file with Step/X_T/eDrawing type must be provided
6.12. All documentation shall be supplied to ISR on PDF files and hardcopies.
6.13. Final report which will include the run in results and all monitored parameters, during
assembly critical measurements report.

7. Environmental conditions.

6.1 Here below the environmental conditions the supplied turbocharger must operate in :

Maximum temperature 55 (ºC)

Minimum temperature - 10 (ºC)
Humidity up to 100%
Height (m) - 400 up to + 800
Sunshine hours per year 3,300
Ultraviolet radiation per year (MJ/m²) 360 up to 600
Rainfall per year (mm) 400 up to 800

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8. Warranty

Turbochargers are warranted for twelve (12) months from date of service or eighteen (18) months
from date of shipping, whichever should occur first.

9. Logistical requirements

9.1. The bidder should supply the ordered product to ISR Railway within 45 days (maximum).
9.2. Based on ISR Railway's requirements, the supplier should store the provided turbocharger in
his place with accordance to the manufacturer requirements, and based the following
conditions (the strictest of them):
9.2.1. All turbocharger openings during storage must be closed by technological caps.
9.2.2. The packaged turbocharger should be stored in a dry, ventilated warehouse with a
relative humidity of 54-75% without the presence of aggressive chemicals.
9.2.3. The storage area should not be directly affected by weather conditions.
9.3. Suppling the turbochargers should be to ISR Railway warehouses - Haifa, Lod, Beersheba
(with accordance to the customer requirements).

10. Training:

10.1. The supplier should provide training in the customer facilities and depos, based the
customer requirements, that should include:
10.1.1. On class training for assembly to the engine and the locomotive.
10.1.2. On class training for making the maintenance and rebuild/overhaul procedure.
10.1.3. On depot training for assembly to the engine and the locomotive.
10.1.4. On depot training for maintenance and rebuild/overhaul procedure.
10.2. The training scheduling should meet the customer requirements.

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