sales program rail - mcv- · pdf filesales program rail edition 1/15 valid ... - sam –...

Power. Passion. Partnership.

Sales Program Rail Edition1/15 validfrom08/2015

2 I Rail I SalesProgram SalesProgramI Rail I 3

02 Contents

04 Certified quality

06 General specifications

07 Engine designation

08 Selection Guideline/Product portfolio -PowerPacks®forrailcars,underfloorinstallation 315kW-700kW -Dieselenginesforpush-pulltrainsandlocomotives 850kW-3300kW

10 Applications

28 References of Diesel engines and PowerPacks® in railcars/push-pull trains and locomotives

30 References of Diesel engines and PowerPacks® in special-purpose rail vehicles

32 Repowering

34 Automation -Allproductsandbenefitsataglance -SAM–ThereliablepartnerforyourPowerPack® -PowerlineforSeries1600andSeries4000 -CaPoSpowerline -CaPoSsmartedition

48 After Sales MTUValueCare

54 Exhaust emissions Exhaustemissionlegislationforrailapplication

59 Conversion table

Con

tent

s


MTU:Certified quality.

MTUisthecorebrandofRolls-RoycePowerSystemsAG,whichisa

world-leadingproviderofhigh-andmedium-speeddieselandgasengines,

completedrivesystems,distributedenergysystemsandfuelinjection

systemsforthemostdemandingrequirements.

Thedevelopment,productionandmaintenanceofdieseltractionsystems

forrailwaytrainsareamongMTU’scorecapabilities–andhavebeen

fornearly100years.Aslongagoas1924,weweredevelopingand

manufacturingproductionenginesforscheduled-servicetrains.In1933,

ourdieselenginesprovidedthemotivepowerforthelegendary“Fliegende

Hamburger”,thefirsthigh-speedrailcar.AndfromtheearlyFiftiesuntil

today,wesuppliedmorethan5,500dieselenginesandPowerPacks®tothe

DeutscheBundesbahn,therebyplayingamajorpartinitsfull-scaleprogram

ofconversiontodieselpower.Theextensiveexperienceandunique

specialistknowledgegainedfromthathistoryandtraditionarethebasisof

ourcomprehensiveexpertiseinsystemengineering.

Weareamongtoday’sleadingprovidersoftractionunittechnologyfor

railwayapplications.Locomotiveandrailcarproducersallovertheworld

placetheirtrustinusassystemsuppliers.Weandourpartnersare

developingtodaythetechnologiesthatwilldriveustomorrow.Andthat

simplymeansthatweoffertherailoperatormore:

moreperformance,moreefficiency–

andmoredependability.

Quality also is our passion:Wearethefirstdieselengine

manufacturermeetingthe

InternationalRailwayIndustry

Standard-IRIS.

MTU

1 IRIS

2 ISO9001

3 ISO14001

4 UIC

5 MTUFriedrichshafenisaQ1suppliertotheDeutscheBahnAG

2 3

4 51


Four-strokedieselenginefortraction>Directinjection

>Liquid-cooled

>VorIn-lineconfiguration

>Suitableformechanical,hydrodynamic,hydrostaticand

electricpowertransmission

PowerDefinitionAllpowerratingsareservicestandardpowerinaccordancewith

UICspecifications.

Ambientairpressure: 1000mbar

Heightabovesealevel: 100m

Intakeairtemperature: 25°C

Charge-aircoolanttemp.: 45°C

FuelconsumptioninaccordancewithDIN/ISO3046

Exhaustemissionstandards:

EU = EUNonroadDirective97/68EC(asamendedby2010/26/EC)

EPA = USRegulation40CFR9,85

UIC = InternationalRailwayAssociation

Pleasenote,specificationsaresubjecttochangewithoutfurthernotice.All

dimensionsareapproximate,moredetailedinformationisincludedwithin

installationdrawings.

ForfurtherinformationonMTURailproductspleasecontactyourmtudistributororvisit:www.mtu-online.com

General specifications

Explanation of the engine designation

Series1800,1600,4000Example:

16V4000R43LAdditionalenginefeatures

Designindex

Application/Powersegment

Application:R=Rail

Series

Cylinderconfiguration:V=V-engine

H=HorizontalIn-lineengine

No.ofcylinders

Gen

eral

Additional engine featuresPoweruprated L

Speed/powerreduced R

PowerPack-aggregat P


MTU PowerPacks® and Engines All engines at a glance.

App

lica

tion

s

kW

500 1000 1500 2000 2500 3000 35000

kW

bhp

500 1000 1500 2000 2500 3000 3500 4000 45000

bhp

422 – 523 bhp

315 – 390 kW

758 – 940 bhp

565 – 700 kW

925 bhp

690 kW

1140 – 4425 bhp

850 – 3300 kW

Page,

Engine Type

MTU PowerPackSeries 1800

Page 10

MTU PowerPackSeries 1600

Page 14

Series 1600Page 16

Series 4000Page 16

Railcars PowerPacks®forrailcars-Underfloorinstallation

Push-pull trains/locomotives Enginesforpush-pulltrainsandlocomotives

315 kW - 700 kW Page10-15

690 kW - 3300 kW Page16-27


H

L W

GRA-0626

PowerPacks® for railcars Underfloor installation

315 kW – 390 kW(422 bhp - 523 bhp)

Dimensions:PowerPacks®withstandardequipment

> Forunderfloorinstallation

> Horizontallymountedinlineengines

PowerPack® Model 6H1800R81P 6H1800R82PRated Power kW (bhp) 315 (422) 335 (449)Speed rpm 1800 1800Exhaust Emissions EUStageIIIA EUStageIIIA

compl./EPA compl./EPA

Tier3compl. Tier3compl.

Fuel Consumption

atRatedPower g/kWh 216 214

l/h(gal/h) 82.0(21.7) 86.4(22.8)

atBestPoint g/kWh 198 198

Drive systems1) DM/DH/DE DM/DH/DE

PowerPack® – Dimensions & Masses Length(L)2) mm 2600-3600 2600-3600

(in) (102.4-141.7) (102.4-141.7)

Width(W)2) mm 2100-2800 2100-2800

(in) (82.7-110.2) (82.7-110.2)

Height(H)2) mm 770-850 770-850

(in) (30.3-33.5) (30.3-33.5)

Mass,dry2) kg 2900-3600 2900-3600

(lbs) (6393-7936) (6393-7936)

Mass,wet2) kg 3050-3900 3050-3900

(lbs) (6724-8598) (6724-8598)

Engine Main Data No.ofCylinders/Arrangement 6/inline 6/inline

Bore/Stroke mm 128/166 128/166

(in) (5.0/6.5) (5.0/6.5)

Displacement/cyl. l(cuin) 2.13(130) 2.13(130)

Displacement,total l(cuin) 12.8(781) 12.8(781)

Further variations on demand 1)Drivesystems:DM=dieselmechanical;DH=dieselhydraulic;DE=dieselelectrical2)dependingonscopeofsupply

6H1800R83P 6H1800R84P360 (483) 390 (523)1800 1800EUStageIIIA EUStageIIIA

compl./EPA compl./EPA

Tier3compl. Tier3compl.

218 210

94.6(25.0) 98.7(26.1)

198 198

DM/DH/DE DM/DH/DE

2600-3600 2600-3600

(102.4-141.7) (102.4-141.7)

2100-2800 2100-2800

(82.7-110.2) (82.7-110.2)

770-850 770-850

(30.3-33.5) (30.3-33.5)

2900-3600 2900-3600

(6393-7936) (6393-7936)

3050-3900 3050-3900

(6724-8598) (6724-8598)

6/inline 6/inline

128/166 128/166

(5.0/6.5) (5.0/6.5)

2.13(130) 2.13(130)

12.8(781) 12.8(781)

Rai

lcar

s



315 kW – 390 kW(422 bhp – 523 bhp)

Dimensions:PowerPacks®withstandardequipment


> Horizontallymountedinlineengines

PowerPack® Model 6H1800R75P 6H1800R75LPRated Power kW (bhp) 315 (422) 335 (449)Speed rpm 1800 1800Exhaust Emissions EUStageIIIB EUStageIIIB

Fuel Consumption


l/h(gal/h) 75.53(19.95) 80.03(21.14)




(in) (102.4-141.7) (102.4-141.7)

Width(W)2) mm 2100-2800 2100-2800

(in) (82.7-110.2) (82.7-110.2)

Height(H)2) mm 770-850 770-850

(in) (30.3-33.5) (30.3-33.5)

Mass,dry2) kg 2900-3600 2900-3600

(lbs) (6393-7936) (6393-7936)

Mass,wet2) kg 3050-3900 3050-3900

(lbs) (6724-8598) (6724-8598)

Engine Main Data No.ofCylinders/Arrangement 6/inline 6/inline

Bore/Stroke mm(in) 128/166 128/166

(5.0/6.5) (5.0/6.5)



Further variations on demand

6H1800R85P 6H1800R85LP360 (483) 390 (523)1800 1800EUStageIIIB EUStageIIIB

202 208

87.30(23.06) 97.33(25.71)

183 183

DM/DH/DE DM/DH/DE

2600-3600 2600-3600

(102.4-141.7) (102.4-141.7)

2100-2800 2100-2800

(82.7-110.2) (82.7-110.2)

770-850 770-850

(30.3-33.5) (30.3-33.5)

2900-3600 2900-3600

(6393-7936) (6393-7936)

3050-3900 3050-3900

(6724-8598) (6724-8598)

6/inline 6/inline

128/166 128/166

(5.0/6.5) (5.0/6.5)

2.13(130) 2.13(130)

12.8(781) 12.8(781)

Rai

lcar

s

1)Drivesystems:DM=dieselmechanical;DH=dieselhydraulic;DE=dieselelectrical2)dependingonscopeofsupply

H

L W

GRA-0626



565 kW – 700 kW(758 bhp - 938 bhp)

DimensionsandMasses:PowerPacks®withstandardequipment


PowerPack® Model 12V1600R70P 12V1600R70LPRated Power kW (bhp) 565 (758) 625 (838)Speed rpm 2100 2100Exhaust Emissions EUStageIIIB EUStageIIIB

Fuel Consumption


l/h(gal/h) 127.98(33.8) 139.31(36.8)




(in) (157.5-204.7) (157.5-204.7)

Width(W)2) mm 2100-2800 2100-2800

(in) (82.7-110.2) (82.7-110.2)

Height(H)2) mm 850-900 850-900

(in) (31.5-35.4) (31.5-35.4)

Mass,dry2) kg 5000-6500 5000-6500

(lbs) (11023-14330) (11023-14330)

Mass,wet2) kg 5200-6700 5200-6700

(lbs) (11464-14770) (11464-14770)

Engine Main Data No.ofCylinders/Arrangement 12 12


(4.8/5.9) (4.8/5.9)

Displacement/cyl. l(cuin) 1.75(106.8) 1.75(106.8)

Displacement,total l(cuin) 21.0(1281.5) 21.0(1281.5)

Further variations on demand1)Drivesystems:DM=dieselmechanical;DH=dieselhydraulic;DE=dieselelectrical2)dependingonscopeofsupply

12V1600R80P 12V1600R80LP660 (885) 700 (938)1900 1900EUStageIIIB EUStageIIIB

199 200

155.06(40.96) 166.14(43.88)

195 195

DE DE

4000-5200 4000-5200

(157.5-204.7) (157.5-204.7)

2100-2800 2100-2800

(82.7-110.2) (82.7-110.2)

850-900 850-900

(31.5-35.4) (131.5-35.4)

5000-6500 5000-6500

(11023-14330) (11023-14330)

5200-6700 5200-6700

(11464-14770) (11464-14770)

12 12

122/150 122/150

(4.8/5.9) (4.8/5.9)

1.75(106.8) 1.75(106.8)

21.0(1281.5) 21.0(1281.5)

Rai

lcar

s


Enginesfor push-pull trains and locomotives

690 kW – 1200 kW(925 bhp - 1609 bhp)

Dimensions:Engineswithstandardequipment

> Fornewlocomotivesorrepowering

> Economicalspacerequirements

Engine Model 12V1600R50 8V4000R41RRated Power kW (bhp) 690 (925) 850 (1139)Speed rpm 1800 1500Exhaust Emissions EUStageIIIB UICII

Fuel Consumption


l/h(gal/h) 164(43.3) 208.9(55.2)


Engine – Dimensions and Masses Length(L) mm(in) 1850(72.8) 1915(75.4)

Width(W) mm(in) 1200(47.2) 1380(54.3)

Height(H) mm(in) 1200(47.2) 1800(70.9)

Mass,dry kg(lbs) 2300(5071) 4700(10362)

Mass,wet kg(lbs) 2500(5512) 5020(11067)

Engine Main Data No.ofCylinders 12 8


(4.8/5.9) (6.5/7.5)

Displacement/cyl. l(cuin) 1.75(106.8) 4.06(248)

Displacement,total l(cuin) 21.0(1281.5) 32.5(1983)

1)EUIIIAtypeapproved,EUIIIAcertificateavailable

8V4000R43 8V4000R43L1000 (1341) 1200 (1609)1800 1800EUStageIIIA EUStageIIIA

compliant1)/ compliant1)/

UICIIIA UICIIIA

206 206

248.2(65.2) 297.8(78.7)

194 194

2000(78.7) 2000(78.7)

1565(61.6) 1565(61.6)

1860(79.0) 1860(79.0)

5220(11508) 5220(11508)

5570(12280) 5570(12280)

8 8

170/210 170/210

(6.7/8.3) (6.7/8.3)

4.77(291) 4.77(291)

38.2(2331) 38.2(2331)

Push

-pul

l/Lo

co.

L

H

W0555



1380 kW – 1800 kW(1851 bhp - 2414 bhp)


> Welldifferentiatedchoiceofenginesspanningwiderangeofpoweroutputs

> Highpower-to-weightratiosforlightweighttrains

Engine Model 12V4000R41R 12V4000R43Rated Power kW (bhp) 1380 (1851) 1500 (2012)Speed rpm 1500 1800Exhaust Emissions UICII EUStageIIIA

compliant1)/

UICIIIA

Fuel Consumption


l/h(gal/h) 324.2(85.7) 370.5(97.9)



Width(W) mm(in) 1390(54.7) 1562(61.5)

Height(H) mm(in) 1795(70.7) 2015(79.3)

Mass,dry kg(lbs) 6190(13646) 6800(14991)

Mass,wet kg(lbs) 6630(14616) 7280(16049)



(6.5/7.5) (6.7/8.3)




12V4000R41L 12V4000R43L1650 (2212) 1800 (2414)1860 1800UICII EUStageIIIA

compliant1)/

UICIIIA

206 210

409.5(108.2) 455.4(120.3)

198 190

2405(94.7) 2386(93.9)

1390(54.7) 1562(61.5)

1795(70.7) 2015(79.3)

6190(13646) 6800(14991)

6630(14616) 7280(16049)

12 12

165/190 170/210

(6.5/7.5) (6.7/8.3)

4.06(248) 4.77(291)

48.7(2978) 57.2(3491)

Push

-pul

l/Lo

co.



1500 kW – 1800 kW(2012 bhp - 2414 bhp)


> Welldifferentiatedchoiceofenginesspanningwiderangeofpoweroutputs

> Highpower-to-weightratiosforlightweighttrains

> MeetingemissionsregulationsEUStageIIIB

Engine Model 12V4000R64 12V4000R84Rated Power kW (bhp) 1500 (2012) 1800 (2414)Speed rpm 1800 1800Exhaust Emissions EUStageIIIB EUStageIIIB

Fuel Consumption


l/h(gal/h) 367.4(97.1) 436.5(115.3)



Width(W) mm(in) 1696(66.8) 1696(66.8)

Height(H) mm(in) 2001(78.8) 2001(78.8)

Mass,dry kg(lbs) 7700(16979) 7700(16979)

Mass,wet kg(lbs) 8230(18147) 8230(18147)



(6.7/8.3) (6.7/8.3)



Series4000-04enginesportfoliomeetingEUStageIIIBwillbecompletedwith8Vmodels.ForfurtherinformationpleasecontactyourMTUdistributor.

Push

-pul

l/Lo

co.

12V4000R541800 (2414)1800EPATier3

CarbULELcompl.

199

430.0(113.5)

onrequest

2670(105.1)

1696(66.8)

2001(78.8)

7700(16979)

8230(18147)

12

170/210

(6.7/8.3)

4.77(291)

57.2(3491)



1700 kW – 2400 kW(2280 bhp - 3218 bhp)


> Cutting-edgetechnologywithbuilt-inpotential

> Uniquelylowemissionsandconsumption

> MarketleaderinitsclassforEuropeandiesellocomotives

Engine Model 16V4000R41R 16V4000R43RRated Power kW (bhp) 1700 (2280) 2000 (2682)Speed rpm 1500 1800Exhaust Emissions UICII EUStageIIIA

compliant1)/

UICIIIA

Fuel Consumption


l/h(gal/h) 405.5(107.1) 498.8(131.8)



Width(W) mm(in) 1405(55.3) 1562(61.5)

Height(H) mm(in) 1815(71.5) 2015(79.3)

Mass,dry kg(lbs) 7400(16314) 8175(18023)

Mass,wet kg(lbs) 7880(17373) 8770(19334)



(6.5/7.5) (6.7/8.3)


Displacement,total l(cuin) 65(3967) 76.3(4656)


16V4000R43 16V4000R43L2200 (2950) 2400 (3218)1800 1800EUStageIIIA EUStageIIIA

compliant1)/ compliant1)/

UICIIIA UICIIIA

206 205

546.0(144.3) 592.8(156.6)

196 196

2865(112.8) 2865(112.8)

1562(61.5) 1562(61.5)

2015(79.3) 2015(79.3)

8175(18023) 8175(18023)

8770(19334) 8770(19334)

16 16

170/210 170/210

(6.7/8.3) (6.7/8.3)

4.77(291) 4.77(291)

76.3(4656) 76.3(4656)

Push

-pul

l/Lo

co.



2000 kW – 2400 kW(2682 bhp - 3218 bhp)


> Cutting-edgetechnologywithbuilt-inpotential

> Uniquelylowemissionsandlowconsumption

> MeetingemissionsregulationsEUStageIIIB

Engine Model 16V4000R64 16V4000R74Rated Power kW (bhp) 2000 (2682) 2200 (2950)Speed rpm 1800 1800Exhaust Emissions EUStageIIIB EUStageIIIB

Fuel Consumption


l/h(gal/h) 482.6(127.5) 533.5(140.94)



Width(W) mm(in) 1696(66.8) 1696(66.8)

Height(H) mm(in) 2001(78.8) 2001(78.8)

Mass,dry kg(lbs) 9200(20282) 9200(20282)

Mass,wet kg(lbs) 9773(21546) 9773(21546)



(6.7/8.3) (6.7/8.3)



Series4000-04enginesportfoliomeetingEUStageIIIBwillbecompletedwith8Vmodels.ForfurtherinformationpleasecontactyourMTUdistributor.

16V4000R84 16V4000R542400 (3218) 2400 (3218)1800 1800EUStageIIIB EPATier3

CarbULELcompl.

199 199

573.35(151.46) 592.8(156.6)

190 onrequest

3140(123.6) 3140(123.6)

1696(66.8) 1696(66.8)

2001(78.8) 2001(78.8)

9200(20282) 9200(20282)

9773(21546) 9773(21546)

16 16

170/210 170/210

(6.7/8.3) (6.7/8.3)

4.77(291) 4.77(291)

76.3(4666) 76.3(4666)

Push

-pul

l/Lo

co.


WL

H


2700 kW – 3300 kW(3621 bhp - 4425 bhp)


> Outstandingpowerdensity.Unbeatenpower-to-weightratio

> Upto3,300kWfor4-axlelocomotivesand6-axlelocomotives

Engine Model 20V4000R43 20V4000R63RRated Power kW (bhp) 2700 (3621) 2700 (3621)Speed rpm 1800 1800Exhaust Emissions EUStageIIIA EUStageIIIA

compliant1)/ compliant/

UICIIIA UICIIIA

Fuel Consumption


l/h(gal/h) 676.6(178.8) 664(175)



Width(W) mm(in) 1562(61.5) 1562(61.5)

Height(H) mm(in) 2015(79.3) 2015(79.3)

Mass,dry kg(lbs) 9850(21716) 10400(22932)

Mass,wet kg(lbs) 10520(23193) 11070(24410)



(6.7/8.3) (6.7/8.3)




Push

-pul

l/Lo

co.

20V4000R43L 20V4000R63 20V4000R63L3000 (4023) 3000 (4023) 3300 (4425)1800 1800 1800EUStageIIIA EUStageIIIA EUStageIIIA

compliant1)/ compliant/ compliant/

UICIIIA UICIIIA UICIIIA

210 206 206

759.0(200.5) 745(197) 819(216)

194 197 195

3335(131.5) 3335(131.5) 3335(131.5)

1562(61.5) 1562(61.5) 1562(61.5)

2015(79.3) 2015(79.3) 2015(79.3)

9850(21716) 10400(22932) 10400(22932)

10520(23193) 11070(24410) 11070(24410)

20 20 20

170/210 170/210 170/210

(6.7/8.3) (6.7/8.3) (6.7/8.3)

4.77(291) 4.77(291) 4.77(291)

95.4(5822) 95.4(5822) 95.4(5822)


ReferencesDiesel engines and PowerPacks® in railcars/ push-pull trains and locomotives

High-Speed-Trains and Locomotives

Railcars

Deutsche BahnV2901 x 1000 kW

CNR Dalian DL class1 x 2700 kW

Siemens ER 20D„EURORUNNER“1 x 2000 kW

PKP CargoST 461 x 1800 kW

Siemens/AlstomBB 4750001 x 2000 kW

PESA Link2 x 390 kW

Hitachi IEPPowerPack1-5 x 700 KW (depending on class)

Bombardier Turbo StarPowerPack®2 x 390 kW

RotemClass 220003 x 360 kW

Ref

eren

ces

©Siemens

Alstom Lint 41PowerPack®1-4 x 390 kW(depending on class)


ReferencesDiesel engines and PowerPacks® for special-purpose rail vehicles

Remote- controlled shunter

Fire Fighting and Rescue Train

Auxiliary locomotive for tunnel operations

Railroad inspection vehicle

Rotary Snow-Plow

Grinding train

Track layer

Rail crane

Overhead line inspection railcar

> Individualtractionsystemsolutions

> Flexibilityindesignandinstallation

FurtherappplicationswithMTUsystemsolutionsaree.g.:

-Locomotivesforundergroundrailways

-Mountainrailways

> Emissionsoptimizedenginesfortunneloperationswithparticlefilter/

exhaustcatalyst

Ref

eren

ces


Foreconomicalreasons,manyrailwaycompaniesandlocomotiveoperatorshavedecidedtorepowerolderlocomotivesandrailcarswhichareingoodgeneralconditionwithmoderndieselengines.Duetotheirhightechnicalstandards,MTUenginesfulfillalltechnicalcriteriaforrepoweringprojects:

> Economicalalternativetonewprocurement> Reducedinvestmentcosts> Increasedavailabilityequaltothatofanewvehicle> Individualsolutionstosuitexistingsysteminterfaces

MTUisyourcompetentpartnerforasuccessfulrepoweringproject,weoffereverythingyourequire:

> Activesupportprovidedbyaprofessionalengineeringservice duringallphasesofarepoweringproject> Designandrealisationofthetractionplant> Enginesadaptabletoexistingparameters> Reliableandsturdyengineswithlowfuelandlubeoil consumptionrates> Longmaintenanceintervalsandlowlife-cyclecosts> Compactdimensionsforeasyinstallationinexisting enginerooms> Lowinstallationandmaintenanceeffort> Theaccessoriesincorporateclearlydefinedinterfacesandare mountedtotheengineinsuchamannerastobeeasily accessibleformaintenanceoperations> Excellentpower-to-weightratiospermitinstallationofhigher powerratingswithoutexceedingpermissibleaxleloads> QualifiedsupportbytheMTUProductSupportorganisation> Meetallapplicableexhaustgasandnoiseemissionslimitvalues

Repoweringwith MTU Diesel engines

Rep

ower

ing


Automation systemsAll products and benefits at a glance

Aut

omat

ion

Automation system SAM

Components – PowerPack Automation – MR2 –PEM

Advantages at a glance –Centralinterface forcompletesystem – Fornew-production andrepowering projects

MTU PowerPacks®for Railcars Series1800

Series1600

MTU Engines for Railcar Trainsets and LocomotivesSeries1600

Series4000

Page 36

Powerline CaPoS (Capacitor CaPoS Power System) smart edition

– ADEC – Ultracap – Ultracap (ECU7/ECU9) – DC/DCvoltage – MDEC(ECU4) transformer – PAUEngine – Connectioncable– PAUTraction– POM

– Specialrail – Electricalsystem – Integralcharger automationsystem voltage – Standalone– Centralinterface 16VDC-154VDC component forcompletesystem – CANinterface – Enclosurerating– Fornew-production – Maintenance-free IP66 andrepowering – Maintenance-free projects– Certifiedforrail applications

38 44 46


Systemhighlightsandbenefits:

> Completesystemsupplied fromonesinglesource> Modulardesign> Optimizeddiagnostic function

> IntelligentCANbus technology> Fastprojectimplementation> Easyintegration

TheSystemPowerPackAutomation(SAM)isaninnovativehigh-endtechnologyofMTUforrailvehicles–e.g.forrailcars.PowerPackAutomation(SAM)optimizesthecontrol,regulationandmonitoringoftheentiredrivesystem.Representingamodularsystem,itensuresperfectadaptationofthedrivesystemtothemostcomplexoperatingconditionsinrailapplications.

PowerPackAutomation(SAM)allows:> Easyintegrationinnewor–incaseofretrofits–existingvehicle controlsystems> Flexibleadaptationtothevehicleoritscomponentsandto project-specificrequirements> Automaticpoweradjustmentor,ifrequired,engineshutdown bytheintegratedsafetysystemaswellasallotherrequired monitoringandsafetyfunctions> Tractionoptimizationbytheintegratedloadmanagement (torquecontrol)featuredependingontheconsumersconnected (e.g.generator,compressoretc.)

Thus,thenewPowerPack®generationprovides> Highpowerefficiency> Lowestfuelconsumption> Minimumexhaustemissionswhichareconsiderablybelowthe statutoryrequirements(e.g.validEUStageIIIAand EUStageIIIB)> Flexibleandstandardizedinterfacesolutions

Diagnosisandmaintenance> Interfacetothecentralrailcarcomputersystem,includingthe drivesystemcomponents.

SAM – The reliable partner for your PowerPack®

The smart module.

SAM = Service and Application Module

Aut

omat

ion

SCR-CAN

SCRcontrolunitFramemodule2Ureadosing

unit;Heatingvalveandureanozzle

SCRmufflerwithcatalyst2

Ureatank2/3Ureasupplyunit2

1Enginemounted2PowerPackmounted3VehiclemountedSAM=ServiceandApplicationModule

Additional components for current engine series with emissions regulations EU Stage IIIB

EnginemanagementsystemwithintegratedSCRsystem–Typicalconfiguration–

Vehiclecontrolsystem

Brakingcontrolsystem

PowerPack®auxiliary

PTOs

Reversing control system

Gearbox control system

SAM

Vehiclecontrolcommands

Diagnosisinterface

EngineManagement1

Enginesensorsandcontrolelements


powerline–MTU’sautomationsystemfortraindriveunits–representsastepintoawholenewfutureoftechnologyforrailvehicles.EvenwithonlythebasiccomponentsADEC,POMandPAU,thepowerlineautomationsystemmakestheintegrationoftheengineintothelocomotiveasimpleprocess.POM,likeADEC,isanelectronicmodulemountedpermanentlytotheengine.Control,regulationandmonitoringareallpartofthepackagethatMTUdelivers.Withthehelpofoptimizedinterfacetechnology,theengineisquickandeasytoinstall.

MDEC/ADECenginecontrolsystemsTheenginecontrolsystems— MDEC(MTUDieselEngineControl)forSeries4000R41— ADEC(AdvancedDieselEngineControl)forSeries1600,4000

R03/R04aresystemsthathavebeendevelopedandproducedbyMTUspecificallyforusewiththeverylatesthigh-perfor-mancedieselenginetechnology–designednotonlyforfullcontroloftheCommonRailtechnologyintheSeries4000,butaboveallforthemanagementoffrequentextremeloadsandsuddenloadchanges,whichcanbeovercomeeffortlesslyandsmoothlyusingthissystem.

Themostimportantfeaturesataglance:— Componentmountedonandwiredintotheengine— Integratedcontrolandmonitoringsystem— Fuel-optimizedoutputregulation— Integratedsafetyandself-testsystem— Databusinterface

POM(PowerOutputModule)forSeries1600,4000R03/R04Modulewithactuatingfunctionforthestartermotorandalternator,withthefollowingfeatures:— Componentmountedontheengine— Starterrelayandotherconventionalpowerroutingnotrequired— Optimizationofstart-upprocess;startermotormonitoringwith

engagingfunction— Alternatorfunctionmonitoring— Linebreakandshortcircuitmonitoring— Batteryvoltagemonitoringwithstart-upinterventionplus

statusindicationanderrorreportfunction— ADECandPOMlinkedviaCANdatabus— Fullyautomatedstart-upcontrolwithADEC

Automationpowerline for Series 1600 and Series 4000

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omat

ion

ADEC - EngineManagement POM - InterfaceModule


PAU - TractionPAU - Engine


Aut

omat

ion

powerlineadditionalmoduleforrepoweringofdiesel-electriclocomotivedrivesystemsPAUTraction(PowerAutomationUnit)Moduleforthemonitoring,control,regulationandsystemintegrationofthetractiongeneratorandrectifier,withthefollowingfeatures:— Fordrivesystemswithdirect-currentseries-woundengines— Optimizedoutputregulation,configuredforthedieselengine— Generator,rectifierandvehicleenginemonitoring— Fieldweakeningcontrolforvehicleengine— Wheel-slipprotection— Integratedsafetyfunctions(e.g.powershut-off)— Ethernetinterface(e.g.servicelaptop)— Faultringbuffer— Locomotivesafetyfunctions— Specificationincludescurrentandvoltagetransformersplus

amplifierforgeneratorexcitation

powerlinefornewlocomotivesorrepoweringwithSeries1600and4000

PAUEngine(PowerAutomationUnit)Moduleforthemonitoring,controlandsystemintegrationofperipheralenginecomponents,withthefollowingfeatures:— Stand-alonecomponentwith(redundant)CANopeninterface

tovehiclecontrolsystem— Transferofallengine-relatedoperationaldataincluding

diagnosticstothevehiclecontrolsystem— Additionalmonitoringandcontrolofperipheralenginesystems · Coolantlevelmonitoring · Fuelpumpactuation · Airfiltermonitoring · Integratedsafetyfunctions · Dataoutputforfuelconsumptionindicator · Ethernetdiagnosisinterface(e.g.servicelaptop) · Faultringbuffer · Coolingfanregulation



ADEC = AdvancedDieselEngine ControlMDEC = MTUDieselEngine

Control

PAU = PowerAutomationUnitPOM = PowerOutputModule

Aut

omat

ion

Peripheralenginecomponents–Fuelpump–Coolingfan

–Coolantlevelswitch

StartermotorAlternator

MTUamplifierGeneratorexcitation

TractiongeneratorMTUVoltagetransformer+

currenttransformer

MTUpowerlinePAUEnginefornewlocomotivesorrepowering

MTUpowerlinePAUTractionforrepoweringof

diesel-electriclocomotives

Cab


PAUEngine

MDEC ADEC

POM

PAUTraction

+

+

24Vbatteryor

MTUCaPoSstartersystem

24Vbatteryor

MTUCaPoSstartersystem

StartermotorAlternator

1) 2)

1)forSeries4000R412)forSeries1600,Series4000R03/R04


Innovationrightfromthestart.CaPoSisaninnovativeUltraCapvoltagesupplysystemwhichobviatestheneedforconventionalstarterbatteriesinrailroadapplications.

CaPoSusescapacitortechnologytooptimizestartupbehavior.ThenumberofUltraCapmodulestobeuseddependsonthetypeofengineinvolvedanditsbreakawaytorque.CaPoSmaybeusedautonomouslyorinconjunctionwiththepowerlineautomationsystem.

Themostimportantfeaturesataglance:— Autonomousandmodularconstruction— Maintenance-freesystem— Significantreductionsinweightandvolumecomparedwith conventionalstarterbatteries— Optimizedcold-startingproperties— Lowlife-cyclecosts— Novoltageinterruptionduringstart-up— On-boardvoltageof16V–154Vpossible— Wired-upcompletesystem— CANinterfacewithpowerline

AutomationCaPoS – Capacitor Power System for Series 1600, 1800 and 4000

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omat

ion

1) 2)

CaPoSfornewlocomotivesorrepowering

Cab


Loksteuerung

MDEC ADEC

POM*Startermotor

Startermotor

On-Boardbattery

Voltagetransformer

(DC/DC)

CaPoS

Dependingonengine,useofbetween1to5

UltraCapmodules

UltraCapmodule

1

UltraCapmodule

5

CaPoSwithpowerline-Sampleforthe12V4000

CaPoS withpowerline

PAU

1)forSeries4000R412)forSeries1600,Series4000R03/R04*OptionalforSeries1600


3)

CaPoS smarteditionfornewlocomotivesorrepowering

Cab


Loksteuerung

ADEC

POM* Starter

2)

MDEC

Starter

1)

MR2

Starter

On-BoardBattery24VDC

CaPoS

1to2Modules

Module1

Module2

CaPoS smart edition

1)forSeries18002)forSeries4000R41(8V)3)forSeries1600,Series4000R03(8V)*OptionalforSeries1600

Aut

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ion

Reliablepowerrightfromthestart.CaPoSsmarteditionwasespeciallydevelopedforheavyanddutyapplicationsandprovidesthehighenergyrequiredbythe24VDCstartersduringthestartingsequence.CaPoSsmarteditionusescapacitortechnologytooptimizestartupbehavior.Thenumberofmodulestobeuseddependsonthetypeofengineinvolvedanditsbreakawaytorque.

Themostimportantfeaturesataglance:— Autonomousandmodularconstruction— Maintenance-freesystem— Significantreductionsinweightandvolumecomparedwith conventionalstarterbatteries— Optimizedcold-startingcapabilities— Lowlife-cyclecosts— Novoltageinterruptionduringstart-up— On-boardvoltageof24VDC— Integratedself-monitoringsystemwithinterfacetovehicle controlsystem— IntegratedDC-/DCconverterforautomaticalrecharging— IP66protection

AutomationCaPoS smartedition – Capacitor Power System for Series 1600, 1800 and 4000

CaPoS smart edition – Sample for the 12V 1600


GettingthemostoutofyourMTUenginesandsystemsisofparamountimportance.That’swhyweofferMTUValueCare,acompleteportfolioofproductsandservicesdesignedtohelpmaximizebothperformanceanduptime.

TheMTUValueCareportfolioincludesglobalsupportandserviceproductsthroughValueService;genuinesparepartsandtopqualityconsumablesthroughValueSpares;andremanufacturedenginesandservicepartsthroughValueExchange.Nomatterwhereyouareorwhatyouneed,we‘realwaysreadytoprovidevaluablesupportthroughourworldwideMTUservicenetwork.

ValueServiceProducts:Remote ServicesIdentifyingfaultsearly,beforetheyturnintounwantedcomplications,savesvaluableservicetimeandhelpsyoumakequickoperationaldecisions.AsapartofValueService,RemoteServicesisapowerfuldiagnosticsolutionthatlinksyoudirectlytoarecordoftheactivityofyourMTUenginesandsystemsthroughasecureInternetconnection.AtelemetricdevicewithinRemoteServicesstoresselectedinformationandtransmitsitinrealtimeoratpredeterminedintervals.Importantenginedatasuchasoiltemperature,currentlocationandoperatinghourscanbeconvenientlyretrievedforanalysis,evenremotelyfromafar-awayworksite.AllyouneedisacomputerwithanInternetconnection.

RemoteServicescanbeorderedasanoptiononanMTUengine.IfyoualreadyhaveanMTUengine,RemoteServicesisalsoavailableasaretrofit.TheminimumdurationforaRemoteServicesUserAgreementis2years,afterwhichtimeit‘sautomaticallyextendedfor6months.

MaintenanceSolutions:> CustomizedCare:professional,plannedmaintenance solutionsfromMTU> ExtendedCoverage:providingcoveragebeyondyour standardwarrantyonyourMTUenginesandsystems> AnnualCheck:ayearlyprofessionalinspectionofyour MTUenginesandsystemsbyMTUexperts

Inaddition,wecanprovidefurthervalue-addedservices:>Technicaldocumentation>Training>RAMS-LCC-Analysis

ValueSpares:> Genuineparts> Topqualityconsumables(lubricants,coolants,filters)

ValueExchange:> RemanufacturedParts> RemanufacturedEngines> RemanufacturedPowerPacks> EngineOverhaul

MTUValueCareA valuable portfolio of products and services

Aft

erS

ales


Series and emissions qualificationOverview of MTU engines

Emis

sion

s

Engine model UIC II UIC IIIA

MTU PowerPacks® for Railcars1 Series1800

2 Series1600

MTU Engines for Railcar Trainsets, Push-Pull Trains and Locomotives 3 Series1600

4 Series4000

8V/12V/16V4000R41

8V/12V/16V/20V4000R431)

20V4000R53

20V4000R63

12V/16V4000R54

12V/16V4000R64/74/84


EU Stage EU Stage US EPA Tier3 US EPA Tier3 US EPAIIIA IIIB (line haul (line haul Tier 4icompliant certified loco) loco) Carb (NRMM) compliant ULEL compl. compliant

1 2 3 4


ExhaustGasAftertreatment InternalEmissionTechnology

SelectiveCatalytic

Reduction(SCR)

DieselParticulate

Filter(DPF)

DieselOxidation

Catalyst(DOC)

ExhaustGas

Recirculation

(EGR)

Two-Stage

Turbocharging

AdvancedCommonRail

FuelInjection

Key technologies for emission reductionMTU engine technology

Emis

sion

s

Engine model Exhaust Gas Aftertreatment

SCR DPF DOC

Railcar Series1800

Series1600

Locomotive Series1600

Series4000

Internal Emission Technology

EGR 2st Turbo- Advanced charging CR


UIC(InternationalRailwayAssociation)Initscodex624theUIChasestablishedemissionlimitsforrailtractionengines,whicharebindingforallitsmembers.

Exhaust emissions

Stage Power Pn NOx HC CO Partic. Date Speed nn g/kWh g/kWh g/kWh g/kWhUICII Pn≤560kW 6.0 0.6 2.5 0.25 2003

Pn≤560kW 9.5 0.8 3.0 0.25 2003

nn≥1000rpm

Pn≤560kW 9.9 0.8 3.0 0.25 2003

nn≥1000rpm

USA-EPARailRegulation40CFR9,85,etal.On6May2008theUSEPAhaspublishedthefinalrule„40CFRParts,9,85etal.“forlocomotiveengineslessthan30literspercylinder.Thislawregulatestheemissionlimitvaluesforallraildieselengines.

Line-haulLocomotives

Engine category Take effect PM NOx HC in year g/bhp-hr g/bhp-hr g/bhp-hrRemanufactured 2008,as 0.22 8.0 1.00

Tier0without available

separateloop 2010required

intaikeaircooling

Remanufactured 2008,as 0.22 7.4 0.55

Tier0with available

separateloop 2010required

intaikeaircooling


Tier1 available

2010required


Tier2 available

2013required

NewTier3 2012 0.10 5.5 0.30

NewTier4 2015 0.03 1.3 0.14

Switch-haulLocomotives

Engine category Take effect PM NOx HC in year g/bhp-hr g/bhp-hr g/bhp-hrRemanufactured 2008,asavail. 0.26 11.8 2.10

Tier0 2010required

Remanufactured 2008,asavail. 0.26 11.0 1.20

Tier1 2010required

Remanufactured 2008,asavail. 0.13 8.1 0.60

Tier2 2013required

Tier3 2011 0.10 5.0 0.60

Tier4 2015 0.03 1.3 0.14

Emis

sion

s

Railcarpropulsionengines

Stage Power Pn NOx HC CO Partic. Date* Cylinder g/kWh g/kWh g/kWh g/kWh displacem. HC+NOx (g/kWh) IIIA >130kW 4.0 3.5 0.2 2006

IIIB >130kW 2.0 0.19 3.5 0.025 2012

*Dateforplacingonthemarketofengines,typeapprovaloneyearearlier.

EU-Rail97/68/ECLocomotivepropulsionengines

Stage Power Pn NOx HC CO Partic. Date* Cylinder g/kWh g/kWh g/kWh g/kWh displacem. HC+NOx (g/kWh) IIIA 130-560kW 4.0 3.5 0.2 2007

>560kW 6.0 0.5 3.5 0.25 2009

>2000kW 7.4 0.4 3.5 0.2 2009

Vh,z>5l

IIIB >130kW 4.0 3.5 0.025 2012


USA-EPANonroadRegulation(40CFR89,40CFR1039and40CFR1068)

Dieselengines

Power Pn NOx HC CO Particul. Date as kW g/kWh g/kWh g/kWh g/kWh of model NOx + NMHC yearTier 4Pn<8 7.5 7.5 8.0 0.4A 2008

8≤Pn<19 7.5 7.5 6.6 0.4 2008

19≤Pn<37 4.7 4.7 5.5 0.03 2013

37≤Pn<56 4.7 4.7 5.0 0.03 2013

56≤Pn<130 0.4 0.19 5.0 0.02 2015B

130≤Pn<560 0.4 0.19 3.5 0.02 2014C

Pn>560 3.5 0.19 3.5 0.04 2015Tier 4 GensetPn>560 0.67 0.19 3.5 0.03 2015

A hand-startable,aircooleddirectinjectionenginesmaybecertifiedtoTier2 standardsthrough2009andtoanoptimalPMstandardof0.6g/kWh startingin2010B PM/CO:fullcompliancefrom2012;NOx/HC:Option1(ifbankedTier2 creditsused)–50%enginesmustcomplyin2012-2013;Option2(ifno Tier2creditsclaimed)–25%enginesmustcomplyin2012-2014,withfull compliancefrom31December2014C PM/CO:fullcompliancefrom2011;NOx/HC:50%enginesmustcomplyin 2011-2013

Notes


1kW =1.360PS g = 9.80665m/s21kW =1.341bhp π = 3.141591bhp =1.014PS e = 2.718281oz =28.35g1lb =453.59g 1lb = 16oz1shortton =907.18kg 1shortton = 2000lbs1lb/bhp =447.3g/PSh 1ftlb = 1.356Nm1lb/bhp =608.3g/kWh 1ft/min = 0.00508m/s1gal/bhp(US)=4264g/kWh pDiesel = 0.85kg/l1kWh =860kcal 1lb/sqin = 0.069bar(1psi)1cal =4.187J 1mmHg = 1.333mbar (133.3Pa)1BTU =1.055kJ 1mmH

2O = 0.0981mbar

(9.81Pa)1inch =2.540cm T(K) = t(°C)+273.151sq.inch =6.542cm2 t(°C) = 5/9x(t(°F)-32)1cu.inch =16.387cm3 t(°C) = 5/4xt(°R)1foot =3.048dm 1foot = 12inches1sq.foot =9.290dm2 1yard = 3feet1mile =1.609km 1mile = 5280feet1naut.mile =1.853km 1naut.mile= 6080feet1UKGallon =4.546l1USGallon =3.785l1USBarrel =0.159m3 =42USGallons

Energy: 1J=1Ws=1VAs=1NmPower: 1W=1VA=1Nm/sForce: 1N=1kgm/s2

Pressure: 1Pa=1N/m2(1bar=105Pa)MEP(bar) =Pcyl(kW)x1200 n(1/min)xVcyl(l)Torque(Nm) =Pges(kW)x30000 n(1/min)xπ

Conversion Table

Applicationsalesprograms:—Marine—PowerGen—C&I,Agricultural,Mining—Oil&Gas—OnsiteEnergy

Notes

MTUFriedrichshafenGmbHMTUAsiaPteLtdMTUAmericaInc.Rolls-RoycePowerSystemsCompanies

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