Railway as Force for Japanese Modernization |
This article explains the history of domestic production of
railway rolling stock in Japan; it covers steam and internal
combustion locomotives, as well as carriages and wagons,
including internal combustion railcars. Electric trains forming
the heart of today’s railways in Japan are explained in
another article.
The first railway line in Japan opened in October 1872
between Tokyo and Yokohama under direct control of the
Meiji government. It was a public passenger and freight
railway modelled on the Liverpool and Manchester Railway
(L&MR) opened in Great Britain in September 1830, and
brought unseen western technology to a modernizing Japan
just emerging from the feudal shogunate system.
In November 1871, a year before the first railway opened
in Japan, the Meiji government sent a mission of 48 people, led by the Minister of the Right Tomomi Iwakura (1825-83) to Europe and America. They returned 22 months later after crossing the Atlantic from America to Great Britain. The officials, who had seen the fruits of the Industrial Revolution, drew up a framework for Japan’s modernization based on the slogan of ‘Enrich the country, strengthen the military, and encourage new industry’.
‘Enrich the country, strengthen the military…’ aimed to
construct an affluent state with mining and manufacturing as
its industrial base; ‘… encourage new industry’ aimed at the
evolution in Japan of the Industrial Revolution that had begun
in Great Britain. This meant a shift from the existing system
based on agriculture to one based on mining, manufacturing
and trade. The goal for Japanese industry was to assure domestic manufacture.
At the time, there was an urgent need to introduce the
scientific knowledge and new technology required for the
railway, which was essential for industry as well as for mining
and metallurgy, shipbuilding, machinery, telegraphy, electrical
supply, construction (architecture) and printing. The quickest
way was to invite engineers from the West to give on-the-job
training to Japanese who would go on to take the lead in
each industry. After the early training, using the advice of
British engineers for the government-run railways on Honshu
(Imperial Government Railways or IGR), and of American
engineers for railways for the Hokkaido Development
Commissioners used to spearhead the opening up of
Hokkaido, everything, from surveying and construction to
management, was done by Japanese. Private railways were
built in Kyushu and Shikoku under the guidance of a German
railway engineer who also supervised the construction of an
industrial line at Besshi copper mine in Shikoku.
Both the IGR and the private railways were constructed to
the narrow-gauge specification of 3 feet 6 inches (1067 mm).
When railway construction first started, the Engineer-in-Chief
E. Morell (1840–71) asked the government to select a gauge
but they knew nothing about such matters and adopted the
gauge in Morell’s proposal. This narrow gauge still continues
to cause technical problems for Japanese railways today.
However, Japanese railway engineers successfully achieved
high speeds and good safety on narrow-gauge tracks over
weak alluvial ground and on grades. They also continued to
make great efforts to develop technology aimed at switching
to ‘broad’ gauge (standard gauge) and to manufacture rolling stock domestically.
Most of the ‘officially hired foreigners’ were British
because the Meiji government had sought financial
assistance from Great Britain as a consultant, and the
Industrial Revolution in Britain had created a surplus of
skilled railway engineers with both specialized technical
skills and leadership skills after leading railway construction in the British colonies of South Africa, Australia, Ceylon (now
Sri Lanka), and India. However, these advisers gradually
returned home as Japanese trainees took over the core of
the practical work, such as civil engineering, operations,
management, and manufacturing. It was part of the terms
of their employment, as was the high remuneration they
received. Given these circumstances, there were high
expectations for Japan’s railways as a major force in the country’s modernization. |
Introduction of Technology for Manufacturing Rolling Stock |
This section discusses the introduction of technologies
supporting domestic production of rolling stock. ‘Domestic
production’ here means the manufacture of products in
Japan (by Japanese) even using imported items and
materials. In general, introduction of new technology is a
phased process of digestion and establishment. For rolling
stock, it consists of the following five phases.
Phase 1: In this phase, the new technology is introduced as
a complete system; locomotives, carriages, and wagons are
imported as semi-finished products from the catalogue of
an overseas rolling-stock manufacturer and are assembled
and used under the tutelage of foreign mentors. In this
stage, the Japanese trainees mastered practical skills and
technical expertise by assembling and operating products.
Use of rolling stock causes wear and tear, so spare parts for
maintenance and repair are imported too.
From this point on, the technical level for domestic
production is indicated by the degree of responsibility borne
by Japanese engineers in (a) production planning, (b)
design of mechanisms and parts, (c) parts manufacturing, and (d) assembly and adjustment.
Phase 2: In this phase, some machine parts are manufactured
under the tutelage of skilled mentors; carriages and wagons
are remodelled and manufactured because these processes
require only low skill levels. Locomotives are not handled
because they require advanced technological competence acquired through both technical training and on-the-job
training in inspection and repair.
Phase 3: This phase builds on the experience from phase
2. Although foreign-made products are used for major
rolling-stock components, other parts are manufactured
domestically and the rolling stock is assembled and
completed. Manufacture of rolling stock during the mid-Meiji
era by IGR and private railways comes in this category.
Phase 4: In this phase, everything from materials to
parts as well as essential machine tools is manufactured
domestically. Japan started mass-production of steel from
government steelworks in 1904 and it was supplied to
domestic manufacturers of rolling-stock main frames and
running gear.
Phase 5: In this last phase, the mastered technologies and
expertise are exported and technical assistance is provided
to other countries.
Based on this background, we will discuss examples
of the manufacturing of coaches and wagons first, and then locomotives. |
Domestic Production of Carriages and Wagons |
With the exception of internal combustion railcars discussed
later, carriages and wagons have no motive power and are
hauled by locomotives. Their role is to carry passengers and
freight, so railways always have large fleets of both. When
the first line between Tokyo and Yokohama opened, it used
58 carriages and 75 wagons imported from Great Britain.
These arrived as semi-finished products. The wooden bodies
and main-frame components, and the steel parts, such
as bogies and wheel sets, were assembled by Japanese trainees working under foreign instruction, work which provided them with very beneficial practical experience. The imported items were then used as patterns with only steel parts being imported subsequently. Four-wheeled carriages were manufactured at the IGR Kobe Works in 1875, and at the Shimbashi Works in 1879, continuing to about 1900. The main domestically produced parts at that time were wooden bodies. These were manufactured by experienced carpenters who drew on skills amassed up until the Edo era in building Japanese-style boats, houses, and furniture.
The standard four-wheel carriage had a length between
23 ft (7010 mm) and 25 ft (7620 mm), and a wheelbase of
12 ft (3658 mm) or 12.5 ft (3810 mm). Domestic steel for the
carriage main frame had to wait until 1904, when government
steelworks started producing steady supplies; the same was
true for materials for rails and bridges.
Meanwhile, nine large four-wheel bogie wooden carriages
were used at the opening of the IGR line between Osaka
and Kobe; one third-class carriage was manufactured at
the Kobe Works. It consisted of two, linked four-wheel, third-class
cars with 10 seats in each divided open passenger
space and a total capacity of 100 passengers. It had a
prototype Adams Bogie with a composite structure of wood
and iron. Four-wheel bogie carriages had better running
stability and ride comfort than four-wheel carriages, making
them better suited to mass transport, so demand increased
yearly. Fifty-six were imported from Great Britain when the
Tokaido main line opened in July 1889. In addition to the IGR
Shimbashi and Kobe works, the works of private railways
such as San’yo Railway, Kansai Railway and Nippon Railway
built many distinctive carriages and wagons. The designers and builders were all Japanese.
The very best of these carriages belonged to the Imperial
Household for private use. The first Imperial carriage (Mark
1) was a four-wheel wooden carriage built at the IGR Kobe
Works under the supervision of W. M. Smith (1842–1906),
the first locomotive superintendent (chief mechanical
engineer or CME). It is a masterpiece combining the
latest technology of the day with the elegance of beautiful
Japanese ornamentation. The Meiji Emperor made the return
trip in it at the opening of the IGR line between Kyoto and
Kobe in 1877. It was designated as a ‘railway monument’ by
the former Japanese National Railways (JNR) in 1958, and
as a ‘national cultural property’ in 2003. It is the oldest extant four-wheel Japanese wooden carriage.
At the end of the Russo-Japanese War in 1905, the Diet
promulgated the 1906 Railway Nationalization Act to create the IGR network as quickly as possible by nationalizing
the lines of 17 private railway companies, including Nippon
Railway, San’yo Railway, and Kyushu Railway. Nationalization
had two objectives: to connect and develop the regions, and
to secure rapid military transport in emergencies. A unified
transport network required railways throughout Japan to
adopt the same narrow gauge but the private railways had
used unique designs so the use of standardized rolling
stock had to wait for rolling stock standards from the Railway
Agency established in 1908.
In 1910, the Railway Agency designed carriages with a
length of 17 m, such as the Hoha 12000, which had a larger
body cross-section than existing carriages. From 1919, it
designed four-wheel bogie standard carriages with a length
of 20 m, such as the Naha 22000, serving lines throughout
Japan. Domestic steel was used for the main frames and
running gear of the Railway Agency-designed wooden
four-wheel bogie carriages, but truss rods (main-frame
reinforcements) were still being fitted on both sides of the
underframe. These carriages were manufactured by three
Railway Agency-designated companies: Kisha Seizo (Tokyo
Works, formerly Hiraoka Works), Nippon Sharyo Seizo (now
Nippon Sharyo), and Kawasaki Shipyard Co.
In response to freight demands, the wagon capacity was
also increased from 10 to 15 tons or more, and large four-wheel
bogie wagons appeared. The wagon main frames
and bodies were initially wood and steel, but changed to
domestic steel, and various wagons tailored to shippers’
needs appeared on lines across Japan.
Carriage design changed when the Ministry of Railways
was created in 1920. After some tragic accidents, plans
were made to strengthen the bodies of wooden carriages;
a fishbelly underframe and semi-steel body with frame and
outer panels of steel and wood interior were adopted. These
include the general-purpose Oha 30 and the wide-window
express Oha 35. Private rolling stock works designated
by the Ministry of Railways built them. When JNR was established in 1949, Suha 42 was designed for main-line
expresses, and the next surge in demand for passenger
transport led to mass-production of Naha 10 for express
trains using a monocoque structure to lighten the body
and the underframe. Pallet- and container wagons became
widespread with mass-production of the large Wamu 80000
covered wagons, container wagons, refrigerator cars and
wagons exclusively for car transport; these were used to
transport freight between hubs. Tanker wagons for chemical and petroleum became increasingly bigger. A new design of light bogie was developed with a roller bearing to make transportation more efficient. This system became central to freight transport and is still in use today. |
Photo: Hoha 12000 carriage built in 1910 (The Railway Museum)
Photo: Wamu 1 covered wagon with 15-ton capacity (The Railway Museum)
Photo: Oha 35 wide-window express carriage (The Railway Museum)
Photo: Taki 50000 tank wagon for transporting gasoline (The Railway Museum) |
Internal Combustion Railcars
The 1923 Great Kanto Earthquake inflicted tremendous
damage on Tokyo and other cities including the railways.
As alternative transport to the devastated trams, the Tokyo
Municipal Electric Bureau made an emergency import of
800 Ford model-T truck chassis to build buses with wooden
bodies. These buses were convenient and cheap to operate
compared to railways and trams, so bus operators grew
throughout Japan. The impact was felt most strongly by
small to medium local private railways. As a countermeasure
to buses running along roads parallel to tracks, railways
created new stops and started operating cheap, cost effective,
single railcars powered by internal combustion.
The kidojidosha (automobile type railcar) developed by
Nippon Sharyo is a good example.
The same phenomenon occurred on the Ministry of
Railways regional lines where carriages and wagons were
hauled by steam locomotives. However, the Ministry did not ask for help from private rolling-stock manufacturers, who were ahead in terms of internal combustion engine
technology, design and manufacture. Instead, the Ministry
of Railways designed Kihani 5000, a unique, small, four-wheel
internal combustion railcar, which was manufactured
by Nippon Sharyo in 1929. However, Kihani 5000 design
concept differed from that of the small lightweight internal
combustion railcars of private manufacturers. The body
steel thickness was the same as the steel four-wheel
bogie carriage stipulated by the Ministry. The engine and
running gear followed Ministry policy of using domestic
parts, but there was no suitable large automotive engine,
so a remodelled gasoline marine engine (40 PS) by Ikegai
Tekkosho was installed under the floor. The transmission was mechanical and the radiator was installed in front of the roof like German internal combustion railcars. The running gear was a four-wheel single bogie (bearing spring with sliding bearing) with improvements for comfort. However, despite its small size Kihani 5000 weighed 15.5 tons due to the sturdy body and main frame. This weight did not match
the low output of the remodelled Ikegai Tekkosho marine
engine, and erformance was poor. Although there were
foreign engines with large horsepower, the requirement to
use domestic goods doomed Kihani 5000 to failure. In 1931,
Nippon Sharyo and Kawasaki Sharyo each manufactured a Kihani 36450 large internal combustion/electrical railcar. A
gasoline engine (200 PS) by Ikegai Tekkosho was installed
and connected directly to a 135-kW DC generator powering
two 80-kW traction motors in the bogie. This was the first
domestic internal combustion (petrol)/electrical railcar but
it was scrapped later because the 49.1-ton weight was too heavy for the power output.
Kiha 36900 (later Kiha 41000) is an example of a
domestic medium-size internal combustion (petrol) railcar
with lighter weight matching the four-wheel bogie engine
output. The Ministry’s policy on internal combustion (petrol)
railcar design was threefold. First, it should operate as a
single-car train without considering impact at the front of the
mainframe; when out of service it should be coupled to the
back of a train. Second, the construction and composition of all parts should be lightened, regardless of compatibility
with existing parts or standards. Third, the Ministry itself
would develop a petrol underfloor engine using domestic
parts. The 36 Kiha 41000 railcars completed in April 1933
had a body length of 15,500 mm and an unladen weight of
20.0 tons. The Ministry-designed GMF13 petrol engine (100
PS) was installed under the floor and the bogie was a TR26
bar-truck constructed of band steel with roller bearings. Kiha 41000 performed well and 136 units were mass-produced by
private rolling stock works by 1936. They were in widespread
operation throughout Japan, mainly on provincial lines. In
1935, Kiha 42000 appeared with a body length of 19,000 mm
and higher passenger capacity. The front was streamlined, and an underfloor GMH17 (150 PS) petrol engine was fitted. It was used widely for passenger transport, along with Kiha 41000, and 62 units were manufactured by 1937. |
Photo: Wamu 80000 covered wagon (The Railway Museum)
Photo: Kiha 41000 medium-size gasoline railcar (The Railway Museum)
Photo: Series Kiha 82 DMU for limited express services (The Railway Museum)
Photo: Kiha 17 diesel railcar (The Railway Museum)
Photo: Series Kiha 58 DMU for ordinary express services (The Railway Museum)
Photo: End car of Asakaze limited express (Tokyo–Hakata) composed of Series 20 air-conditioned sleeping carriage (The Railway Museum)
Photo: The other end car of Asakaze with power generator for lighting and air-conditioning (The Railway Museum) |
The successors to Kihani 36450 internal combustion
(petrol)/electrical railcar were the two Kiha 43000 railcars
completed by Kawasaki Sharyo in 1937 inspired by
successful operation of the streamlined Fliegende Hamburger diesel/EMU express in Germany in 1933. Kiha 43000 was a
streamlined diesel electrical railcar with a directly connected
150-kW generator and underfloor 240-PS horizontal supercharged engine designed in collaboration by the Ministry, Niigata Tekkosho, Ikegai Tekkosho, and Mitsubishi Shipyard. Three-engine models were manufactured; two 80- kWDC motors were mounted on the bogie on the coupled side and they were operated as multiple units consisting of
three carriages with an intermediate trailer between.
Fuel rationing started as WWII intensified and there
was a sharp drop in the operation frequency of internal
combustion railcars as the war drew to an end. With the
1949 creation of JNR and improvements in fuel supply, large
diesel railcars replaced models using substitute fuels, such
as natural gas and coal gas during fuel rationing. This was
followed by completion of Kiha 44000 in August 1952, an
internal combustion (diesel)/electrical railcar fitted with a
Ministry-designed standard DMH17 diesel engine (150 PS).
In addition, an improved version of the torque-converter
hydraulic transmission developed before the war was fitted to Kiha 42500 and Kiha 44500. Its good performance in multiple unit control meant that postwar Japanese internal combustion railcars were configured with hydraulic multiple unit control combining DMH17 diesel engines with hydraulic transmissions (TC-2, DF115). Series Kiha 10 were manufactured from 1953 as the first mass-produced hydraulic transmission internal combustion railcar. It was followed in 1956 by Series Kiha 55 for local expresses and Kiha 20 for general use; both had a larger body cross-section. The next railcars (Kiha 50, 51, and 52) had two built-in engines for higher power output on lines with steeper grades.
1960 marked the start of the high economic growth
period. As living standards rose, line electrification and
the change to internal combustion traction for top-class
trains led to more frequent and faster services as well as
repeatedly revised railway timetables. The ‘bonneted’ Kiha 81 internal combustion express railcar with two horizontal
DMH17H engines (180 PS), appeared in 1960, and was
modified and improved to Kiha 82 with gangways and high
driver’s cab for the October 1961 timetable revision. Kiha 58 was mass-produced for express trains; diesel expresses
were operated on non-electrified lines throughout Japan and
the increased speeds improved rail services. Meanwhile,
Series Kiha 30 commuter internal combustion railcar with
horizontal DMH17H engine was mass-produced from 1961 to
transport commuters from rapidly growing residential areas
around cities. The series of internal combustion railcars was
manufactured by private rolling stock works, such as Niigata Tekkosho, Hitachi Limited, Fuji Heavy Industries, Kisha
Seizo, Tokyu Car Corporation, Nippon Sharyo, Kinki Sharyo,
Teikoku Sharyo, and Kawasaki Sharyo.
At the same time, high-power engines were being
developed to replace two-engine installations. Kiha 60
with 400-PS engine appeared in 1960, and a prototype
internal combustion railcar with 1050-PS CT58 gas turbine
was built as a Japan Association of Rolling Stock Industries
project; it did not get as far as practical use. 1968 marked
the start of mass-production of Series Kiha 181 internal
combustion express railcar with a two-shaft drive and 500-
PS diesel engine. It is still used today. However, the internal combustion railcars designed in the postwar years are wearing out. Some still remain or are preserved, but the railcars that underpinned Japan’s modernization are coming to the end of their days. |
Steam Locomotives |
The construction and mechanisms of steam locomotives
are much more complex than carriages and wagons.
Since domestic production is difficult without advanced
mechanical engineering, practical skills and technical
expertise acquired through first-hand experience, domestic
production proceeded gradually, starting with remodelling of
imported locomotives. The extension of the IGR line to Kyoto
in 1876 led to a shortage of locomotives for passenger trains
so the Kobe Works under the supervision of W. M. Smith,
converted two freight 7010 0-6-0 tender locomotives to
passenger 5100 4-4-0 tender ocomotives. The remodelling
involved dismantling the first driving wheels, removing part of the main frame, and fitting a four-wheel lead bogie. The existing 43-inch (1092 mm) driving wheels were replaced by 55-inch (1397 mm) wheels but the boiler was unchanged. That a locomotive could be remodelled only 4 years after Japan’s first railway opened is an indication of the skills of the Japanese trainee engineers. In 1884, two 4-4-0 tank
locomotives manufactured in 1882 were remodelled into
4-4-0 tender locomotives at the Kobe Works under the supervision of B. F. Wright, the second CME.
A historic project to build the first domestic steam
locomotive at the Kobe Works was launched in 1888 by Richard F. Trevithick (1845–1913), the third CME and
grandson of the inventor of the steam locomotive, Richard
Trevithick (1771–1833). The Class 860 (dubbed No. 221 and
No. 137 before becoming the Class 860) used parts and steel
imported from Great Britain. Its manufacture took 8 months
and it was completed in 1893. It ran between Kyoto, Osaka
and Kobe and achieved good results in trials comparing its
performance with imported locomotives. It had the standard
2-4-2 wheel arrangement of the day but it was a compound
cylinder locomotive, making maintenance difficult. After
operating between Kyoto, Osaka and Kobe, it was transferred
to the Sakhalin Railway where it ended its service. As the first
domestically built steam locomotive, it could be called a
national treasure and its loss without preservation is a gap in Japan’s industrial technology history.
Trevithick eventually returned to Great Britain in 1904
but the Kobe Works manufactured as many as 34 steam
locomotives under his supervision, a testament to the
hard work and perseverance of his trainees, Mori Hikozo
(1867–1958) and Ota Kichimatsu (18??–1927). In 1896, Mori
became manager of the Kobe Works and was in charge of
inspection of completed Class 230 steam locomotives, 41
of which were mass-produced by Kisha Seizo from 1902.
Both men transferred to the Shimbashi Works when the
Kobe Works closed in 1915. Mori then worked for the South
Manchurian Railway before becoming headmaster of Nagoya
Technical College in 1920. Ota transferred to Kawasaki
Shipyard’s Hyogo factory where he worked on the design
and manufacture of the Classes 6700 and 6760 passenger
train steam locomotives using the Railway Agency’s standard
4-4-0 wheel arrangement, and the Classes 9550 and 9600
freight train steam locomotives with the 2-8-0 arrangement.
Design of a standard steam locomotive began
in 1908 when the Railway Agency was created after the
1906–07 railway nationalization. The main reasons were
because the first imported steam locomotives were wearing out, and because maintenance of the diverse types was
difficult and costs were mounting. First, the Railway Agency
manufactured Class 6700 saturated steam passenger train
tender locomotives at Kisha Seizo and Kawasaki Shipyard. It
was then decided to build a larger, high-performance steam
locomotive than existing types to haul limited express trains
between Shimbashi and Shimonoseki. The Railway Agency
sent specifications to locomotive manufacturers in the West for a ‘superheated (steam generated by boiler superheated to 350° to 400°C in superheated tubes) tender locomotive with a 4-6-0 wheel arrangement, and a wheel diameter of 1600 mm’ to import samples for use as reference designs.
In 1911, just 2 months after the order was placed, a Borsig
Class 8850 arrived from Germany, followed by a Schwarzkopf
Class 8800, and North British Class 8700 (saturated steam).
However, the American ALCO Class 8900 that arrived had a
different 4-6-2 wheel arrangement. Class 8850 had a main-bar
underframe cut from thick steel plates and the boiler was
located over the driving wheels. Class 8800 performed well
and the superiority of its superheating was clear. The firebox
of Class 8900 was located over the trailing wheels and the fire grate was large. |
Photo: Class 8620 passenger locomotive (2-6-0) (The Railway Museum) |
The Railway Agency adopted all the good points of these
sample locomotives to design a series that suited Japanese
conditions. First, a Class 6750 superheated version of the
saturated passenger train tender locomotive Class 6700
was manufactured at Kawasaki Shipyard from 1913. Then, a
Class 6760 improved version of the 6750 was manufactured
at Kawasaki Shipyard from 1914. What is more, 687 Class
8620 passenger 2-6-0 tender locomotives were built at
Kisha Seizo and Kawasaki Shipyard from 1914. To save
costs, the leading bogie was connected to the first driving
wheel by a linkage, a design that took operation on curves into consideration.
The same process was followed for freight locomotives.
A Class 9550 saturated steam tender locomotive was produced at Kawasaki Shipyard from 1912. Furthermore, 770
superheated Class 9600 tender locomotives were built at
Kawasaki Shipyard and Kisha Seizo from 1913. Class 6760
and 8620 for hauling passenger trains had standardized main
parts, including boiler, cylinders and 1600-mm wheels for
service compatibility. Unlike the Meiji era, locomotive building
was entrusted to private works chosen by the Railway Agency.
The person in charge of allocating work was the Machining
Section Chief of the Railway Agency, Yasujiro Shima (1870–1946), the first and second chairman of The Japan Society
of Mechanical Engineers (JSME) established in 1924. This method was chosen to promote domestic manufacture by boosting technical skills in mechanical engineering, and railway works became specialized in maintenance and repair of rolling stock. As mentioned before, forty-one Class 230 2-4-2 tank engines were built from 1902 at Kisha Seizo; Class
230 was the first mass-produced tank engine manufactured by Japanese.
When the Railway Agency became the Ministry of
Railways in 1920, new steam locomotives were designed to
run on narrow gauge with the same performance as standard
gauge. First, Kisha Seizo and Mitsubishi Shipyard built 289
units of Class C51 4-6-2 tender passenger locomotive with
large driving wheels of 1750 mm from 1919, followed from
1923 by 380 units of Class D50 2-8-2 tender freight locomotive
built by Kawasaki, Kisha Seizo, Hitachi and Nippon Sharyo.
These locomotives had a larger boiler than previously, and the
fire grate in the firebox over the following wheels was larger to
generate more steam. A main-bar underframe cut from thick
steel plates was used for the first time in Class D50. These
were expanded upon in classes C53 (three cylinders), C55,
and C57, which changed from spoked driving wheels to boxed
driving wheels made of a single piece of cast steel. Class C59
passenger locomotives, and D51 freight locomotive came
out in quick succession. The design of this series of Ministry
locomotives proceeded through collaboration between the
Ministry and private builders and was not confined to steam
locomotives; the same procedure was followed for EF52 DC electric locomotives and EF53 onward.
The Ministry designers took Japan’s topography with
many alluvial plains and grades into account. Before
installing the large boilers used in Western locomotives, it
gave due thought to axle loads that would suit all stretches
of lines. Efficient maintenance work was important as
was standardization of driving wheel diameters and
compatibility of major parts; the Walschaerts valve gear
was also standard. In other words, this group of locomotives
prioritized economics in the design, and it was left to the
advanced technical skills of railway engineers to use them on the various lines.
The same was true of tracks. Trains were operated
thanks to the tremendous efforts of skilled engineers working
on each track section. The age of the steam locomotive truly
was an age when technical skills were central. Of the many
Ministry-designed steam locomotives, the most numerous
was Class D51 2-8-2 tender freight locomotive with 1115
units built from 1926. It was a very significant locomotive in
which all parts were produced domestically. Yasujiro Shima’s
oldest son, Hideo Shima (1901–98), who is also famous as
the father of the shinkansen, was in charge of its design.
Such experience and excellent results made a tremendous
contribution to the postwar mass-production of rolling stock
and the growth of Japanese industry. After WWII, classes
C60, C61 and C62 passenger tender locomotives (all 4-6-4) and Class D62 freight tender locomotive (2-8-4) were
built based on the Ministry-designed steam locomotives.
However, they were soon decommissioned as more lines
became electrified and internal combustion engines
replaced steam. In recent years, passenger operators in the
JR groups are bringing back some old steam locomotives
due to demand for industrial tourism.
As a side note, a steam railcar based on a steam
locomotive towing carriage with a small engine room with
boiler and running gear (cylinders and driving wheels) at
the front was manufactured by Kisha Seizo and adopted by some provincial private railways. The patent belonged to
Kisha Seizo’s Kudo Heijiro and the design was known as the
Kudo Steam Railcar or Kiha 6400 and 6450. They were used
for local transport because they carried less water and coal
than larger steam locomotives. They are the predecessors
of internal combustion railcars, but did not play a prominent
role and were gradually decommissioned and transferred to provincial private railways. |
Photo: Class C51 4-6-2 express passenger locomotive (The Railway Museum)
Photo: Class D51 locomotive photographed in Mito Yard in 1942 (The Railway Museum)
Photo: Modified version of Class C51 with smoke deflectors (The Railway Museum)
Photo: Class D51 locomotive (The Railway Museum) |
Internal Combustion Engines |
Instead of steam boiler, internal combustion locomotives get
their motive power from an internal combustion engine. They
are generally classified into petrol, diesel, or gas-turbine
locomotives, depending on the engine, and into mechanical
or hydraulic, according to the transmission. However,
electric locomotives, where a generator is powered by
an internal combustion engine to drive an electric motor,
were also used. Foreign-built internal combustion (petrol)
locomotives were used by industrial and provincial lines
to replace steam locomotives earlier than on main lines.
A small internal combustion locomotive fitted with a
domestically produced Niigata Tekkosho diesel engine was
manufactured at Amemiya Seisakusho in 1927. In 1931, a
small internal combustion locomotive fitted with an Ikegai
Tekkosho marine diesel engine was built at Hitachi Limited
for Narita Railway, and again at Nippon Sharyo in 1937 for Kashima Sangu Railway.
The Ministry patterns were classes DC10 and DC11
imported from Germany as WWI reparations. They were ordered by the Ministry, and DC11 arrived in Japan in
1929 and DC10 in 1930. Both had a 2-6-2 rod drive wheel
arrangement and were fitted with a diesel engine with the
same output, but different transmission. DC10 had a Krupp
mechanical system (600-PS engine and gearbox) and
DC11 had an Esslingen/MAN electric system (MAN 600-PS
engine and two 190-kW traction motors driven by a 380-kW
generator). As soon as they arrived at Kobe Port, they were
taken to Takatori Works where data was collected for design
of domestically built locomotives by carefully dismantling
them, drawing the parts and then reassembling them. They
took a long time to reach Japan because they were war
reparations and also because diesel locomotive design and
manufacturing technologies were not fully established in
Germany and they were difficult to manufacture. German
diesel locomotive engines were either submarine (U-boat)
engines or modified submarine engine designs; apparently there were no diesel engines for railway use even by 1924 because the size, mass and operational reliability of submarine engines made them ideal for railway engines, demonstrating the excellent and reliable performance of
motors designed for military purposes.
These German diesel locomotives were used to shunt
wagons on the Kobe Port Line and to haul freight trains
between Takatori and Himeji. However, they often broke
down and were taken out of service in 1935 to be scrapped
in Takatori Works during the war.
Design of Japanese-built diesel locomotives began
based on the dismantling and assembly of the German
classes DC10 and DC11 locomotives, and on their
operational performance. The background was economizing
on running costs and other expenses due to the recession in
the early Showa period (1930s). In 1932, eight Class DB10
diesel locomotives were built by Kawasaki Sharyo, Nippon
Sharyo and Hitachi Limited as yard shunters and to haul
very short trains. However, fuel rationing forced them out of
service in 1938 and they were scrapped in 1943. They had
a 0-4-0 wheel arrangement, weighed 10.5 tons, were fitted
with a 60-PS engine made by Ikegai Tekkosho and Kobe Steel, and had a mechanical transmission.
Meanwhile, collaboration started between the Ministry,
private builders and engine manufacturers to design a
new domestic diesel electric locomotive for yard shunting
and hauling freight trains on main lines. The participating
companies were Niigata Tekkosho, Shibaura Seisakusho,
Kawasaki Sharyo, Mitsubishi Electric and Hitachi Limited;
the first Class DD10 locomotive with 2-2-2·2-2-2 wheel
arrangement was completed at Kawasaki Sharyo in 1935.
After test runs, it was put into service at the Oyama Works
but was taken out of service and decommissioned due to
fuel rationing. It was stored in the grounds of the Omiya
Works and dismantled after WWII. It weighed 71.0 tons,
had a Niigata Tekkosho engine (500 PS) and an electrical
transmission with four 100-kW traction motors powered by a 300-kW generator.
Following WWII, JNR built Class DD50 diesel electric
locomotive (4-4) from 1953 and Class DF50 (4-4-4) from 1956.
They were used to haul both passenger and Freight
trains on secondary main lines. DD50 had a driver’s cab
on one side and was fitted with a diesel engine (900-PS)
by Shin Mitsubishi Heavy Industries (now Mitsubishi Heavy
Industries) through a technical partnership with Sulzer of
Switzerland. Four 130-kW traction motors were powered
by a 580-kW main generator connected directly to the
engine. The first production run was three units, with two
operating in tandem on the Hokuriku main line. An improved
model was built in the second production run of three
units in 1955. DF50, meanwhile, was an improved version
of DD50 with the supercharged diesel engine producing
1060-PS and fitted with a steam generator for heating
the carriages. Furthermore, Hitachi and Kawasaki Heavy
Industries produced 1200-PS supercharged diesel engines
through a technical partnership with MAN AG of Germany.
Locomotives with these engines (called DF50-500) were mass-produced from 1958.
Meanwhile, the 4-4 DD11 diesel hydraulic locomotive for shunting (two DMH17B 160-PS engines) appeared in 1954.
From 1957, it was mass-produced as the larger Class DD13
(with two DM31S 3700-PS engines although later models
had two DMF31SB 500-PS engines). At this time, diesel
locomotive manufacturing companies in Japan built one
model of locomotive each using either their own technology
or through a technical partnership with companies in other countries. The purpose was to obtain technical skills in design and manufacturing, and to manufacture prototypes for export.
JNR would borrow and use the locomotives
for some period of time, so they were called ‘borrowed
locomotives.’ Loan periods were broken down mainly into two periods: 1954 to 1962 and 1959 to 1965, and some borrowed locomotives formed the foundation of JNR standard locomotives. These borrowed locomotives were: DD40 (4-4 diesel hydraulic locomotive built in 1960 by Shin Mitsubishi fitted with a 665-PS Mitsubishi Sulzer engine, borrowed from 1960 to 1962, and renamed DD92); DD41 (4-4 diesel electric locomotive built in 1954 by Tokyo Shibaura Denki (now Toshiba) fitted with a 660-PS Cooper-Bessemer engine, borrowed from 1956 to 1958, purchased in 1958, and renamed DD90); DD42 (4-4 diesel hydraulic locomotive
built in 1957 by Nippon Sharyo fitted with two 900-PS Kobe
Steel engines, and borrowed from 1957 to 1958); DD91 (4-2-4 diesel hydraulic locomotive built in 1960 by Shin Mitsubishi
fitted with a 1820-PS Maybach engine, borrowed from 1962
to 1965, and forming the foundation for DD54 manufactured
from 1966); DD93 (4-4 diesel hydraulic locomotive built
in 1961 by Nippon Sharyo fitted with a 1100-PS MAN
Mitsubishi engine, and borrowed from 1962 to 1965); DF90
(6-6 diesel electric locomotive built in 1956 by Hitachi fitted
with a 1680-PS MAN engine, borrowed from 1957 to 1961,
and purchased in 1961); the initial DF91 (6-6 diesel electric locomotive built in 1959 by Hitachi fitted with a 1560-PSMAN engine, borrowed in 1959, and manufactured for export to Taiwan);
DF40 (6-6 diesel electric locomotive built in 1960
by Kawasaki Sharyo fitted with a 1200-PS MAN engine,
borrowed from 1956 to 1958, purchased in 1958, and
renamed DF91); DF41 (6-6 diesel electric locomotive built in
1964 by Kisha Seizo fitted with a 1320-PS Mitsui Burmeister
engine, borrowed from 1959 to 1962, and renamed DF92);
and DF93 (6-6 diesel hydraulic locomotive built in 1960 by
Hitachi fitted with a 1100-PS MAN engine, borrowed from 1962 to 1964, forming the foundation for DF50-500).
The 4-4-4 Class DD51 diesel hydraulic locomotive
(with two DML61L 1000-PS engines although later models
had two DM61Z 1100-PS engines) was mass-produced
from 1962 for use on main lines and played a major role
throughout Japan on non-electrified lines. Also, the 4-2-4
DD54 diesel hydraulic locomotive for secondary main lines
with a lower output than DD51 was manufactured from 1966
by Mitsubishi Heavy Industries based on DD91. It was a diesel hydraulic locomotive fitted with a Mitsubishi Maybach
1820-PS engine and was added by the second production
run in 1967.
For shunting internal combustion locomotives, the
successor to DD13 was Class DE10 with 2-2-2-4 wheel
arrangement and DML61Z engine; it was mass-produced from
1966 and used on lines throughout Japan. These locomotives
can still be seen today but they are wearing out and rolling
stock from the 1960s and 1970s is fast disappearing. |
Conclusion |
This article has briefly explained the changes in domestic
production of steam and diesel locomotives, carriages,
wagons, and internal combustion railcars in Japan from the
first days until now. Around 70% of Japan is mountainous,
and the flat land is largely alluvial coastal plains created
by rivers, so there are limits on use of heavy-axle trains,
such as those in the West. In addition, narrow-gauge tracks
posed many different technical problems from standard gauge. However, such drawbacks were brilliantly overcome, for example by adopting the large cross-sections typical of standard gauge in design of narrow-gauge locomotives, carriages and wagons, making high-speed operations possible. Manufacture of rolling stock was shared between railways’ workshop and private builders and the boost this gave to Japan’s industrial capabilities is an essential part of
our technological history. Design and manufacture of rolling
stock is the product of mechanical engineering as well as various other technologies; it enriches individual technical fields and combines with other fields as it spreads out. It has been a comprehensive industrial bottom-up led by integrated technical systems required for rolling stock manufacturing.
Today, although Japan has reached the stage where
it exports high-speed rail systems to other countries, we
should remember that this is founded on the successive
efforts of railway engineers since the Meiji era to perfect and expand technical systems. |
Photo: Class DF50 diesel electric locomotive (The Railway Museum)
Photo: Class DD13 diesel hydraulic Shunting locomotive (The Railway Museum)
Photo: Class DD51 diesel hydraulic locomotive (The Railway Museum)
Photo: Class DE10 2-2-2-4 diesel hydraulic locomotive (The Railway Museum) |