South African Class 18E, Series 1


The Spoornet Class 18E, Series 1 of 2000 is a South African electric locomotive.
Beginning in 2000, Spoornet embarked on a program to rebuild Class 6E1 locomotives to Class 18E, Series 1 locomotives. Most of the Class 6E1s which had previously been reclassified or modified to Class 16E or Class 17E respectively were rebuilt to Class 18E as well.

Manufacturer

The 3 kV DC Class 6E1 electric locomotive was built for the South African Railways by Union Carriage & Wagon in Nigel, Transvaal, with the electrical equipment supplied by the General Electric Company. Eleven series of Class 6E1 were delivered between 1969 and 1984, with altogether 960 units built. UCW did not allocate builder's numbers to the locomotives which it built for the SAR, but used the SAR unit numbers for their record keeping.

Rebuilding

The rebuilding to Class 18E, Series 1 was done by Transwerk, later renamed Transnet Rail Engineering and then Transnet Engineering, at its Koedoespoort workshops in Pretoria. The rebuilding to Series 1 locomotives ceased in 2009, with 446 units rebuilt from Class 6E1, Series 6 to 11 locomotives, numbered in the ranges from to and to.
Since it was probably not intended at the beginning of the project to rebuild virtually the whole fleet of Class 6E1s to Class 18Es, most of the early rebuildings were done on the newest of the Class 6E1 fleet, Series 8 to 11. One of the reasons was that these series, numbers E1896 and up, already had an air equipment frame brake system, commonly referred to as a brake rack, similar to that intended for the Class 18E which would reduce the overall per-unit cost of rebuilding.
Another consideration was possibly that their bodywork usually required less heavy repairs than the older models in terms of rust and other damage, such as bent panels and frames.
Similar considerations possibly also applied when older Class 6E1s of Series 6 and 7 began to be rebuilt in 2003, since these units in the number range from E1646 to E1895, used the same brake valve as that of the Class 18E. The result by 2013, however, was a fleet of already ageing Class 18Es and ancient Class 6E1s, the latter mostly of Series 6 and older models.

Orientation

The Class 6E1 was a dual cab locomotive and had a roof access ladder on one side only, just to the right of the cab access door. The roof access ladder end was marked as the no. 2 end. A corridor along the centre of the locomotive connected the cabs, which are identical apart from the fact that the handbrake is located in cab 2.
The rebuilt Class 18E locomotive, on the other hand, is a single cab unit since cab 1 was stripped of all controls during the rebuilding to have additional equipment and a chemical toilet installed. Since the driving cab's noise level had to be below 85 decibels, cab 2 was selected as the Class 18E driving cab, primarily based on its lower noise level compared to cab 1, which is closer and more exposed to the compressor's noise and vibration. Another factor was the closer proximity of cab 2 to the low voltage switch panel. The fact that the handbrake was located in cab 2 was not a deciding factor, but was considered an additional benefit.
On some early rebuilds a small plate, about the size of a cigarette packet and engraved with the upgrade information was attached on the cab wall in Cab 1 next to the compressor ventilation opening. The specimen depicted is in error about the original Class 6E series, which was S11 in the case of no. E2167.

Brake systems

Air brakes

The Class 6E1 locomotives were built with an air brake system, consisting of various valves connected to each other with pipes, commonly referred to as a “bicycle frame” brake system. The compressed air pipe is run through bolster and other members and then in a zig-zag pattern under the locomotive's belly to extend its length, which allows the maximum amount of moisture to condense on the way to the reservoirs. As a result, it has multiple pipe connections. A weakness of the system was that, after an accident or even a hard coupling, these pipes tended to develop leaks at the joints which were extremely difficult to repair.
When Class 6E1, Series 7 and earlier locomotives began to be rebuilt, it was necessary to retrofit them with a brake equipment frame or brake rack. Since this already increased the per-unit rebuilding cost, it was decided to simultaneously re-route the compressor pipe away from bolster and other members to the outside of the bodywork on the locomotive's right side, from below and to the right of the cab door to just before the second sandbox lid from the rear end. An added advantage was that the pipe would run cooler and more moisture would condense on the way to the reservoirs. The same modification was not done on locomotives which were rebuilt from Class 6E1, Series 8 and later.

Dynamic brakes

The Class 6E1 locomotives were equipped with regenerative brakes. With regenerative braking, the energy generated by the traction motors is dissipated by the resistor grid banks at the substations, when it is not absorbed by other locomotives in the same electrical section. A stumbling block was that the regeneration equipment at many of the sub-stations along the route was unreliable. Since there was no guarantee that another train would be in the same section to absorb the regenerated energy, there was always the risk that line voltage could exceed 4.1 kV, which would make either the sub-station or the locomotive trip out.
As a result, the rebuilt Class 18E locomotives were equipped with rheostatic braking instead of regenerative braking. With rheostatic braking, the energy generated by the traction motors is dissipated by the resistor grids on the locomotive itself. The rheostatic braking of the Class 18E was superior and very reliable for higher speed trains, compared with the regenerative braking of the older Classes 6E1 and 17E locomotives.

Bogies

The Class 6E1 was built with sophisticated traction linkages on their bogies. Together with the locomotive's electronic wheel-slip detection system, these traction struts, mounted between the linkages on the bogies and the locomotive body and colloquially referred to as grasshopper legs, ensure the maximum transfer of power to the rails without causing wheel-slip by reducing the adhesion of the leading bogie and increasing that of the trailing bogie by as much as 15% upon starting.
During rebuilding, all bogies and traction motors underwent a complete refurbishment. Traction motors were tested back-to-back to ensure quality.

New equipment

The rebuilding included the installation of Alstom micro-processor control technology. New equipment in the totally refurbished Class 18E locomotive include the following:
Beginning in 2009, in an attempt to reduce theft, the 110 V battery bank was relocated from the locomotive sides below the frame and between the bogies to cab 1, where the toilet occupied less than half of the available space. This appears to have been done only with numbers and later. Identifying features are a small grille to the left of the bottom of the cab 1 side door and, in most cases, the remaining battery box frames without side covers.

Appearance

Identifying features

The most obvious visual feature to distinguish the Class 18E from the Class 6E1 is the filled-in driver's windows at the rear end, where the toilet is installed. On the first rebuilds, as observed up to no., the small driver's side window was left in place as a toilet window, but most of these have since also been filled in. The remaining rear windscreen still has the slanted upper edge of the 6E1 windscreens, but the new front windscreens on the Class 18E are rectangular.
On the sides, obvious visual distinctions from the Class 6E1 are the left one of the two large grilles which was removed, with the opening filled in, two new large grilles which are installed in the centre lower sides to serve as air intakes for the rheostatic braking resistance blowers, and a large access door to one of the high-tension compartments, which is installed in place of the rightmost small window which was in the upper side of the Class 6E1. On some Class 18E locomotives, one or more of the remaining small windows were slightly enlarged vertically. On the left side, the air intakes for the air conditioner in the cab are installed between the top three steps of the roof access ladder.
Locomotives which were rebuilt from Class 6E1, Series 6 and 7, have part of the compressed air piping sunk into a recess which runs along the rear of the lower edge of the body on the locomotive's right side, the side opposite the roof access ladder side. On locomotives which were rebuilt from Class 6E1, Series 8 to 11 this pipe was not rerouted.

Lineage identification

All features which distinguished Class 6E1, Series 6 to 11 locomotives from each other, are still present on the Class 18E rebuilds, making it possible to visually determine the Class 6E1 origin of most Class 18E locomotives. Examples are shown in the pictures below.
The locomotive is controlled via resistors over which the voltage is dropped in a configuration of series and parallel electrical circuits. The circuit breakers which switch these circuits, work under very high power and voltage and are all pneumatically operated for insulation purposes. Compressed air is required to open or close the switch actions and air is also used for the weak field Cam Switch, which also switches under very high currents.
Upon starting and in the low notches, the major part of the voltage is dropped over the banks of resistors and all four traction motors are in series. As the driver notches up, some of the resistor banks are cut out via the pneumatically operated switches and the voltage increases across the traction motors. The more resistors which are cut out as the driver notches higher, the more power is developed by the traction motors. At around the locomotive switches to a parallel combination, where the two traction motors per bogie are in a series electrical circuit, while the two bogies are in parallel electrical circuit. Eventually, when all resistors are cut out, the locomotive is operating in full-field.
The locomotives in a consisted set are switched between series and parallel mode automatically, based on speed, overhead voltage and electromotive force. The driver can select "series hold" to force some or all of the locomotives in the consisted set to remain in series mode when overhead voltage is low. If nothing is done, some of the locomotives will switch off under low overhead voltage conditions, to prevent damage to resistors, and switch on again when the voltage improves.

Table of rebuilds

The table lists the original Class 6E1 number, series and year built for each Class 18E, Series 1 locomotive, as well as the year it was rebuilt to Class 18E. All the table columns are sortable.

Count
6E1
no.
6E1
ser.
Year
built
18E
no.
Year
rebuilt
Notes
1E19548198018-0012000
2E19558198018-0022001
3E215011198418-0032001
4E210610198318-0042001
5E214411198418-0052001
6E192081979-8018-0062001
7E216611198518-0072001
8E20749198218-0082001
9E200491981-8218-0092001
10E19128197918-0102001
11E19428198018-0112001
12E19118197918-0122001
13E19788198018-0132001
14E19758198018-0142002
15E19618198018-0152002
16E212510198318-0162002
17E216711198518-0172002
18E19358198018-0182002ex 17E
19E19748198018-0192002
20E20729198218-0202002
21E19028197918-0212002
22E201091981-8218-0222002
23E208910198318-0232002
24E211910198318-0242002
25E19038197918-0252002
26E19808198018-0262002
27E19818198018-0272002
28E20559198218-0282002ex 17E
29E20019198118-0292002ex 16-500A
30E20029198118-0302002ex 16-500B
31E215711198418-0312002
32E212810198418-0322002
33E192581979-8018-0332002ex 16-504A
34E192681979-8018-0342002ex 16-504B
35E191681979-8018-0352002ex 16-501A
36E191781979-8018-0362002ex 16-501B
37E203791981-8218-0372002ex 17E
38E216511198518-0382002
39E209510198318-0392002
40E213110198418-0402002Written off, rebuilt as 18-862
41E19888198118-0412002
42E200991981-8218-0422002
43E212910198418-0432002
44E210210198318-0442002
45E202191981-8218-0452002
46E208710198218-0462002
47E213210198418-0472002
48E218011198518-0482002
49E192981979-8018-0492002ex 16-506B
50E201391981-8218-0502002
51E19638198018-0512002
52E211010198318-0522002
53E209910198318-0532002
54E20789198218-0542002
55E192881979-8018-0552002ex 16-506A
56E20619198218-0562002
57E20839198218-0572002
58E201491981-8218-0582002
59E209310198318-0592002
60E211210198318-0602002
61E19098197918-0612002ex 17E
62E19468198018-0622002ex 17E
63E191881979-8018-0632002ex 16-505A
64E19498198018-0642002ex 17E
65E19998198118-0652002ex 17E
66E218311198518-0662003
67E191981979-8018-0672003ex 16-505B
68E214911198418-0682002
69E19488198018-0692003
70E19628198018-0702003ex 17E
71E216211198418-0712003
72E19588198018-0722003
73E20759198218-0732003ex 17E
74E203891981-8218-0742003ex 17E
75E215311198418-0752003
76E212410198318-0762003
77E19148197918-0772003ex 16-503A
78E19158197918-0782003ex 16-503B
79E20569198218-0792003ex 17E
80E18857197918-0802003
81E210910198318-0812003
82E212610198418-0822003
83E218411198518-0832003
84E19408198018-0842003ex 17E
85E212210198318-0852003
86E18317197818-0862003
87E19048197918-0872003ex 17E
88E213810198418-0882003
89E208810198218-0892003
90E187171978-7918-0902003
91E215211198418-0912003
92E215411198418-0922003
93E20539198218-0932003ex 17E
94E19348198018-0942003ex 17E
95E216311198418-0952003
96E211810198318-0962003
97E182271977-7818-0972003ex 17E
98E217511198518-0982003
99E211610198318-0992003
100E16696197618-1002003ex 16-422A
101E215811198418-1012003
102E210510198318-1022003
103E212310198318-1032003
104E16866197618-1042003
105E215511198418-1052003
106E217411198518-1062003
107E17807197718-1072003
108E211410198318-1082004
109E217311198518-1092004
110E217011198518-1102004
111E214211198418-1112004
112E216411198418-1122004
113E212110198318-1132004
114E213510198418-1142004
115E213710198418-1152004
116E214611198418-1162004
117E214111198418-1172004
118E218211198518-1182004
119E215111198418-1192004
120E217611198518-1202004
121E213010198418-1212004
122E212010198318-1222004
123E213310198418-1232004
124E16876197618-1242004
125E215611198418-1252004
126E209410198318-1262004
127E20799198218-1272004ex 17E
128E213910198418-1282004
129E217211198518-1292004
130E209010198318-1302004
131E212710198418-1312004
132E213610198418-1322004
133E18547197818-1332004
134E17657197718-1342004
135E18427197818-1352004
136E214711198418-1362004
137E17827197718-1372004
138E18607197818-1382004
139E17697197718-1392004
140E217811198518-1402004
141E17477197718-1412004
142E16466197618-1422004
143E16936197618-1432004
144E171061976-7718-1442004
145E214811198418-1452004
146E218511198518-1462004
147E16736197618-1472004
148E214511198418-1482004
149E210010198318-1492004
150E216011198418-1502004
151E211310198318-1512004
152E216111198418-1522004
153E214010198418-1532004
154E214311198418-1542004
155E211710198318-1552004
156E19978198118-1562004ex 17E
157E218111198518-1572004
158E208610198218-1582004
159E17467197718-1592004
160E210410198318-1602005
161E18937197918-1612005
162E215911198418-1622005
163E17426197718-1632005
164E209210198318-1642005
165E17857197718-1652003
166E210110198318-1662003
167E169961976-7718-1672004ex 16-425A
168E217111198518-1682004
169E170061976-7718-1692004ex 16-425B
170E217911198518-1702005
171E216811198518-1712005
172E217711198518-1722005
173E216911198518-1732005
174E209610198318-1742004
175E210310198318-1752004
176E209110198318-1762004
177E210810198318-1772004
178E19668198018-1782005ex 17E
179E209810198318-1792005
180E209710198318-1802005
181E20809198218-1812005
182E170461976-7718-1822005
183E18767197918-1832005
184E179071977-7818-1842005ex 16-407B
185E17306197718-1852005
186E210710198318-1862005
187E178871977-7818-1872005
188E179671977-7818-1882005
189E169761976-7718-1892005
190E16566197618-1902005
191E211510198318-1912005
192E20659198218-1922005ex 17E
193E202591981-8218-1932005ex 17E
194E202091981-8218-1942005ex 17E
195E18998197918-1952005
196E202691981-8218-1962005ex 17E
197E19448198018-1972005ex 17E
198E18787197918-1982005
199E19598198018-1992005
200E19418198018-2002005
201E19698198018-2012005ex 17E
202E19318198018-2022005ex 17E
203E19398198018-2032005ex 17E
204E19728198018-2042005
205E18947197918-2052005
206E17507197718-2062005
207E19458198018-2072005ex 17E
208E17527197718-2082005
209E16526197618-2092005
210E202891981-8218-2102005ex 17E
211E202291981-8218-2112005ex 17E
212E20669198218-2122005ex 17E
213E18737197918-2132005
214E20859198218-2142005ex 17E
215E198681980-8118-2152005ex 17E
216E19378198018-2162005ex 17E
217E20849198218-2172005ex 17E
218E20529198218-2182005ex 17E
219E20449198218-2192005ex 17E
220E19608198018-2202005
221E19328198018-2212005
222E19688198018-2222005ex 17E
223E203091981-8218-2232005ex 17E
224E20709198218-2242005ex 17E
225E19918198118-2252005ex 17E
226E198481980-8118-2262005ex 17E
227E204291981-8218-2272005ex 17E
228E20769198218-2282005ex 17E
229E20519198218-2292005ex 17E
230E203991981-8218-2302005ex 17E
231E179771977-7818-2312005
232E201691981-8218-2322005ex 17E
233E18377197818-2332005
234E204391981-8218-2342005ex 17E
235E20829198218-2352005ex 17E
236E200791981-8218-2362005ex 17E
237E19988198118-2372006ex 17E
238E20459198218-2382005ex 17E
239E20509198218-2392006ex 17E
240E20579198218-2402005ex 17E
241E204091981-8218-2412006ex 17E
242E20639198218-2422006ex 17E
243E20739198218-2432006ex 17E
244E20779198218-2442006ex 17E
245E20679198218-2452006ex 17E
246E203391981-8218-2462006ex 17E
247E203691981-8218-2472006ex 17E
248E19438198018-2482006
249E201891981-8218-2492006ex 17E
250E20609198218-2502006ex 17E
251E20819198218-2512006ex 17E
252E201991981-8218-2522006ex 17E
253E20589198218-2532006ex 17E
254E203491981-8218-2542006ex 17E
255E201191981-8218-2552006ex 17E
256E19768198018-2562006ex 17E
257E20549198218-2572006ex 17E
258E20489198218-2582006ex 17E
259E202491981-8218-2592006ex 17E
260E180571977-7818-2602006ex 17E
261E201591981-8218-2612006ex 17E
262E19008197918-2622006ex 17E
263E19678198018-2632006ex 17E
264E18487197818-2642006ex 16-405A
265E18497197818-2652006ex 16-405B
266E18897197918-2662006
267E202391981-8218-2672006ex 17E
268E20479198218-2682006ex 17E
269E19718198018-2692006ex 17E
270E18437197818-2702006ex 17E
271E20469198218-2712006ex 17E
272E19828198018-2722006ex 17E
273E201291981-8218-2732006ex 17E
274E19368198018-2742006ex 17E
275E200891981-8218-2752006ex 17E
276E204191981-8218-2762006ex 17E
277E16476197618-2772006
278E19928198118-2782006ex 17E
279E19958198118-2792006ex 17E
280E18357197818-2802006
281E20649198218-2812006ex 17E
282E20629198218-2822006ex 17E
283E182771977-7818-2832006ex 17E
284E19068197918-2842006ex 17E
285E200391981-8218-2852006ex 17E
286E192381979-8018-2862006
287E16946197618-2872006
288E19088197918-2882006ex 17E
289E17777197718-2892006ex 17E
290E19478198018-2902006ex 17E
291E20699198218-2912006ex 17E
292E17757197718-2922006ex 17E
293E19388198018-2932006ex 17E
294E181071977-7818-2942006ex 17E
295E19108197918-2952006ex 17E
296E19838198018-2962006ex 17E
297E16906197618-2972006
298E19018197918-2982006ex 17E
299E201791981-8218-2992006ex 17E
300E16916197618-3002006
301E203291981-8218-3012006ex 17E
302E20689198218-3022006ex 17E
303E19898198118-3032006ex 17E
304E203191981-8218-3042006ex 17E
305E19948198118-3052006ex 17E
306E192281979-8018-3062007ex 17E
307E18327197818-3072007ex 17E
308E200591981-8218-3082007ex 17E
309E20008198118-3092007ex 17E
310E19908198118-3102007ex 17E
311E19058197918-3112007ex 17E
312E198581980-8118-3122007ex 17E
313E16966197618-3132007
314E18837197918-3142007
315E19968198118-3152007ex 17E
316E19658198018-3162007ex 17E
317E18387197818-3172007
318E18817197918-3182007
319E202791981-8218-3192007ex 17E
320E19338198018-3202007ex 17E
321E20599198218-3212007ex 17E
322E17166197718-3222007
323E16856197618-3232007
324E198781980-8118-3242007ex 17E
325E200691981-8218-3252007ex 17E
326E17767197718-3262007ex 17E
327E202991981-8218-3272007ex 17E
328E20719198218-3282007ex 17E
329E19648198018-3292007ex 17E
330E19078197918-3302007ex 17E
331E180171977-7818-3312007ex 17E
332E17497197718-3322007ex 17E
333E179271977-7818-3332007
334E192481979-8018-3342007ex 17E
335E17707197718-3352007
336E19938198118-3362007ex 17E
337E19798198018-3372007ex 17E
338E18407197818-3382007ex 16-409A
339E18417197818-3392007ex 16-409B
340E19138197918-3402007ex 17E
341E192181979-8018-3412007ex 17E
342E18617197818-3422007
343E181471977-7818-3432007
344E182671977-7818-3442007ex 17E
345E16846197618-3452007ex 16-427A
346E170161976-7718-3462007ex 16-427B
347E17186197718-3472007ex 16-428A
348E17206197718-3482007ex 16-428B
349E16796197618-3492007ex 16-429A
350E171461976-7718-3502007ex 16-429B
351E16836197618-3512007
352E17326197718-3522007
353E18957197918-3532007
354E17877197718-3542008
355E17226197718-3552007
356E18757197918-3562007
357E17216197718-3572007
358E179571977-7818-3582007
359E18467197818-3592007ex 16-404A
360E18477197818-3602007ex 16-404B
361E178971977-7818-3612007
362E18867197918-3622007
363E186371978-7918-3632007
364E186471978-7918-3642007
365E18337197818-3652007
366E17487197718-3662007
367E17436197718-3672007
368E18537197818-3682007
369E181771977-7818-3692007
370E18887197918-3702007
371E18927197918-3712007
372E169861976-7718-3722008
373E16656197618-3732008
374E18797197918-3742007
375E16926197618-3752008
376E19738198018-3762007
377E17647197718-3772008
378E19708198018-3782008
379E179971977-7818-3792008
380E16756197618-3802008
381E16556197618-3812008
382E17727197718-3822008
383E18978197918-3832008
384E17346197718-3842008
385E17747197718-3852008
386E170561976-7718-3862008
387E183071977-7818-3872008
388E17406197718-3882008
389E17607197718-3892008
390E17517197718-3902008
391E17597197718-3912008
392E18507197818-3922008ex 16-410A
393E18517197818-3932008ex 16-410B
394E171261976-7718-3942008
395E16496197618-3952008
396E18727197918-3962008
397E17246197718-3972008
398E17667197718-3982008
399E17537197718-3992008
400E16956197618-4002008
401E181571977-7818-4012008PRASA
402E181971977-7818-4022009PRASA
403E180471977-7818-4032008PRASA
404E171161976-7718-4042008PRASA
405E17386197718-4052008PRASA
406E182971977-7818-4062008PRASA
407E17587197718-4072009
408E17567197718-4082009
409E182171977-7818-4092009PRASA
410E17717197718-4102009PRASA
411E16896197618-4112009
412E18577197818-4122008PRASA
413E182871977-7818-4132008PRASA
414E186871978-7918-4142008PRASA
415E19578198018-4152009PRASA
416E17557197718-4162009TFR, ex PRASA
417E17867197718-4172009
418E17797197718-4182009TFR, ex PRASA
419E19528198018-4192009PRASA
420E18988197918-4202009PRASA
421E179871977-7818-5002009
422E180271977-7818-5012009
423E180871977-7818-5022009
424E170961976-7718-5032009ex 16-422B
425E16506197618-5042009
426E18367197818-5052009
427E16486197618-5062009
428E192781979-8018-5072009
429E170761976-7718-5082009
430E18747197918-5092009
431E17817197718-5102009
432E18567197818-5112009
433E181171977-7818-5122009
434E18807197918-5132009
435E179471977-7818-5142009
436E18917197918-5152009
437E17637197718-5162009
438E17256197718-5172009
439E17456197718-5182009
440E17316197718-5192009
441E17617197718-5202009
442E17577197718-5212009
443E17737197718-5222009
444E186571978-7918-5232009
445E182571977-7818-5242009
446E170661976-7718-5252009

Illustration

The Class 6E1 series lineage identification features, as well as the liveries which were applied to these locomotives, are illustrated in the following pictures. Note the external compressed air pipe on the right side of locomotives rebuilt from Class 6E1, Series 6 and 7.
;Rebuilt from Class 6E1, Series 6
;Rebuilt from Class 6E1, Series 7
;Rebuilt from Class 6E1, Series 8
;Rebuilt from Class 6E1, Series 9
;Rebuilt from Class 6E1, Series 10
;Rebuilt from Class 6E1, Series 11