A TOGNUM GROUP BRAND

Sales Program Rail

Edition 1/12 valid from 01/2012

Power. Passion. Partnership.

02 04 06 07 08

Contents Certied quality

30

References of Diesel engines and PowerPacks in special-purpose rail vehicles Repowering Automation - Powerline for Series 4000 - CaPoS for Series 4000 - Powerpack Automation After Sales MTU ValueCare Exhaust emissions Exhaust emission legislation for rail application Conversion table

32 General specications 34 Engine designation Selection Guideline - PowerPacks for railcars, underoor installation 315 kW - 660 kW - Diesel engines for push-pull trains and locomotives 850 kW - 3150 kW Applications References of Diesel engines and PowerPacks in railcars/push-pull trains and locomotives 50

44

46 10 28

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Contents

MTU Friedrichshafen GmbH is the core company of the Tognum Group which is one of the world's leading providers of distributed energy systems, as well as diesel engines and complete propulsion/drive systems for all off highway applications. As a strategic holding the Tognum Group combines well-known brands like MTU, MTU Onsite Energy, L'Orange and MercedesBenz industrial engines. The development, production and maintenance of diesel traction systems for railway trains are among MTUs core capabilities and have been for nearly 100 years. As long ago as 1924, we were developing and manufacturing production engines for scheduled-service trains. In 1933, our diesel engines provided the motive power for the legendary Fliegende Hamburger, the rst high-speed railcar. And from the early Fifties through to the Seventies, we supplied more than 4,000 diesel engines to the Deutsche Bundesbahn, thereby playing a major part in its full-scale program of conversion to diesel power. The extensive experience and unique specialist knowledge gained from that history and tradition are the basis of our comprehensive expertise in system engineering. We are among todays leading providers of traction unit technology for railway applications. Locomotive and railcar producers all over the world place their trust in us as system suppliers. We and our partners are developing today the technologies that will drive 1 us tomorrow. And that simply means that we offer the rail operator more: more performance, more efciency and more dependability. Quality also is our passion: We are the rst diesel engine manufacturer meeting the International Railway Industry Standard - IRIS.

1 IRIS 2 ISO 9001 3 ISO 14001

4

4 UIC 5 MTU Friedrichshafen is a Q1 supplier to the Deutsche Bahn AG

5

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MTU

MTU: Certied quality.

Four-stroke diesel engine for traction > Direct injection > Liquid-cooled > V or In-line conguration > Suitable for mechanical, hydrodynamic, hydrostatic and electric power transmission Power Denition All power ratings are service standard power in accordance with UIC specications. Ambient air pressure: 1000 mbar Height above sea level: 100 m Intake air temperature: 25 C Charge-air coolant temp.: 45 C (4000) Fuel consumption in accordance with DIN/ISO 3046 Exhaust emission standards: EU = EU Nonroad Directive 97/68 EC EPA = US Regulation 40 CFR 92 (<750 kW = 40 CFR 89, 40 CFR 1039) UIC = International Railway Association (Codex 624V the UIC) Please note, specications are subject to change without further notice. All dimensions are approximate, more detailed information is included within installation drawings. For further information on MTU Rail products please contact your mtu distributor or visit: www.mtu-online.com

Series 1800, 1600, 4000 Example:

16 V 4000 R 43 L

Additional engine features Application segment/Design index Application: R = Rail Series Cylinder conguration: V = V-engine H = Horizontal In-line engine No. of cylinders

Turbocharged engine Air charge air-cooling External charge air-cooling Air charge air-cooling with mixing capability Additional engine features Power uprated Speed/power reduced PowerPack-aggregat

Series 1800, Series 1600 Series 4000-01 Series 4000-03 Series 4000-04

L R P

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General

General specications

Explanation of the engine designation

Typical Applications

Railcars PowerPacks for railcars - Underoor installation Push-pull trains/locomotives Engines for push-pull trains and locomotives

315 kW - 660 kW Page 10 - 15 690 kW - 3150 kW Page 16 - 27

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Applications

Selection Guideline

PowerPacks for railcars

Underoor installation

315 kW 390 kW

GRA-0626

> For underoor installation > Horizontally mounted inline engines

PowerPack Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power

kW rpm

6H1800R81P 315 1800 EU IIIA compl./ EPA 3 compliant 216 82.0 (21.7) DM

6H1800R82P 335 1800 EU IIIA compl./ EPA 3 compl. 214 86.4 (22.8) DM

6H1800R83P 360 1800 EU IIIA compl./ EPA 3 compliant 218 94.6 (25.0) DM

EU IIIA compl./ EPA 3 compliant

6H1800R84P 390 1800 EU IIIA compl./ EPA 3 compliant 210 98.7 (26.1) DH

EU IIIA compl./ EPA 3 compl.

g/kWh l/h (gal/h)

Drive systems 1) PowerPack Dimensions and Masses Length (L) Width (W) Height (H) Mass, dry 2) Mass, wet 2)

DH

DE

mm (in) mm (in) mm (in) kg (lbs) kg (lbs)

3000 (118.1) 2600 (102.4) 820 (32.3) 2900-3500 (8390-7715) 3050-3700 (6720-8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

3000 (118.1) 2600 (102.4) 820 (32.3) 2900-3500 (8390-7715) 3050-3700 (6720-8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

3000 (118.1) 2600 (102.4) 820 (32.3) 2900-3500 (8390-7715) 3050-3700 (6720-8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

3200 (126.0) 2200 (86.6) 790 (31.1) 3700-4300 (8155-9480) 3900-4500 (8600-9920) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

3200 (126.0) 2200 (86.6) 790 (31.1) 3700-4300 (8155-9480) 3900-4500 (8600-9920) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

2600 (102.4) 2200 (86.6) 790 (31.1) 3200 (7055) 3300 (7275) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

Engine Main Data No. of Cylinders/Arrangement Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

Further variations on demand 1) Drive systems: DM = diesel mechanical DH = diesel hydraulic DE = diesel electrical 2) depending on delivery capacity

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Railcars

Dimensions and Masses: PowerPacks with standard equipment

PowerPacks for railcars

Underoor installation

315 kW 390 kW

GRA-0626

> For underoor installation > Horizontally mounted inline engines

PowerPack Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power

kW rpm

6H1800R75P 315 1800 EU IIIB/EPA 4i 184 69.83 (18.44) DM/DH/DE

6H1800R75LP 335 1800 EU IIIB/EPA 4i 184 74.27 (19.62) DM/DH/DE

6H1800R85P 360 1800 EU IIIB/EPA 4i 184 79.81 (21.1) DM/DH/DE

6H1800R85LP 390 1800 EU IIIB/EPA 4i 184 86.46 (22.31) DM/DH/DE

g/kWh l/h (gal/h)

Drive systems 1) PowerPack Dimensions and Masses Length (L) Width (W) Height (H) Mass, dry 2) Mass, wet 2)

mm (in) mm (in) mm (in) kg (lbs) kg (lbs)

2600 - 3365 (102.4 - 132.5) 2200 - 2695 (86.6 - 106.1) 770 - 835 (30.3 - 32.9) 2900 - 3500 (8390 - 7715) 3050 - 3700 (6720 - 8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)
DH = diesel hydraulic

2600 - 3365 (102.4 - 132.5) 2200 - 2695 (86.6 - 106.1) 770 - 835 (30.3 - 32.9) 2900 - 3500 (8390 - 7715) 3050 - 3700 (6720 - 8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)
DE = diesel electrical

2600 - 3365 (102.4 - 132.5) 2200 - 2695 (86.6 - 106.1) 770 - 835 (30.3 - 32.9) 2900 - 3500 (8390 - 7715) 3050 - 3700 (6720 - 8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

2600 - 3365 (102.4 - 132.5) 2200 - 2695 (86.6 - 106.1) 770 - 835 (30.3 - 32.9) 2900 - 3500 (8390 - 7715) 3050 - 3700 (6720 - 8155) 6/inline 128/166 (5.0/6.5) 2.13 (130) 12.8 (781)

Engine Main Data No. of Cylinders/Arrangement Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

Further variations on demand 1) Drive systems: DM = diesel mechanical 2) depending on delivery capacity

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Railcars

Dimensions and Masses: PowerPacks with standard equipment

PowerPacks for railcars

Underoor installation

565 kW 660 kW

preliminary > For underoor installation > Horizontally mounted inline engines

PowerPack Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power

kW rpm

12V1600R70P* 565 2100 EU IIIB 188 127.98 (33.8) DM/DH/DE

12V1600R70LP* 625 2100 EU IIIB 185 139.31 (36.8) DM/DH/DE

12V1600R80P* 660 1900 EU IIIB 195 155.06 (40.96) DE

g/kWh l/h (gal/h)

Drive systems 1) PowerPack Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) kg (lbs) Mass, dry 2) kg (lbs) Mass, wet 2) Engine Main Data No. of Cylinders/Arrangement Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

3280 (129.2) 2160 (85.0) 1060 (41.8)

On request, please contact your mtu dealer

3280 (129.2) 2160 (85.0) 1060 (41.8)

On request, please contact your mtu dealer

3280 (129.2) 2160 (85.0) 1060 (41.8)

On request, please contact your mtu dealer

12V 122/150 (4.8/5.9) 1.75 (106.8) 21.0 (1281.5)

12V 122/150 (4.8/5.9) 1.75 (106.8) 21.0 (1281.5)

12V 122/150 (4.8/5.9) 1.75 (106.8) 21.0 (1281.5)

Further variations on demand 1) Drive systems: DM = diesel mechanical DH = diesel hydraulic DE = diesel electrical 2) depending on delivery capacity * available April 2013

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Railcars

Dimensions and Masses: PowerPacks with standard equipment

Engines
for push-pull trains and locomotives

690 kW 1200 kW

Dimensions and Masses: Engines with standard equipment

> For new locomotives or repowering > Economical space requirements up to 1200 kW

Engine Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power

kW rpm

12V 1600 R50* 690 1900 EU IIIB

8V4000R41R 850 1500 UIC II

8V 4000 R41 1000 1800 UIC II

8V 4000 R41L 1100 1860 UIC II

8V 4000 R43 1000 1800 EU IIIA compl./ UIC IIIA 206 248.2 (65.2) 2000 (78.7) 1565 (61.6) 1860 (79.0) 5220 (11508) 5570 (12280) 8 170/210 (6.7/8.3) 4.77 (291) 38.2 (2331)

8V 4000 R43L 1200 1800 EU IIIA compl./ UIC IIIA 207 299.3 (79.1) 2000 (78.7) 1565 (61.6) 1860 (79.0) 5220 (11508) 5570 (12280) 8 170/210 (6.7/8.3) 4.77 (291) 38.2 (2331)

g/kWh l/h (gal/h) Engine Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) Mass, dry kg (lbs) Mass, wet kg (lbs) Engine Main Data No. of Cylinders Bore / Stroke mm (in) Displacement/cyl. Displacement, total
* available April 2013

205 166 (43.9) 1850 (72.8) 1200 (47.2) 1200 (47.2) 2200 (4850) 2350 (5180) 12 122/150 (4.8/5.9) 1.75 (106.8) 21.0 (1281.5)

204 208.9 (55.2) 1915 (75.4) 1380 (54.3) 1800 (70.9) 4700 (10362) 5020 (11067) 8 165/190 (6.5/7.5) 4.06 (248) 32.5 (1983)

207 249.4 (65.9) 1915 (75.4) 1380 (54.3) 1800 (70.9) 4700 (10362) 5020 (11067) 8 165/190 (6.5/7.5) 4.06 (248) 32.5 (1983)

212 281.0 (74.2) 1915 (75.4) 1380 (54.3) 1800 (70.9) 4700 (10362) 5020 (11067) 8 165/190 (6.5/7.5) 4.06 (248) 32.5 (1983)

l (cu in) l (cu in)

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Push-pull/Loco.

Engines
for push-pull trains and locomotives

1380 kW 1800 kW

Dimensions and Masses: Engines with standard equipment

> Well differentiated choice of engines spanning wide range of power outputs > High power-to-weight ratios for lightweight trains

Engine Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power

kW rpm

12V4000R41R 1380 1500 UIC II

12V4000R41 1500 1800 UIC II

12V4000R41L 1650 1860 UIC II

12V4000 R43 1500 1800 EU IIIA compl./ UIC IIIA 203 366.9 (96.9) 2386 (93.9) 1562 (61.5) 2015 (79.3) 6800 (14991) 7280 (16049) 12 170/210 (6.7/8.3) 4.77 (291) 57.2 (3491)

12V4000R43L 1800 1800 EU IIIA compl./ UIC IIIA 207 448.9 (118.6) 2386 (93.9) 1562 (61.5) 2015 (79.3) 6800 (14991) 7280 (16049) 12 170/210 (6.7/8.3) 4.77 (291) 57.2 (3491)

g/kWh l/h (gal/h) Engine Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) Mass, dry kg (lbs) Mass, wet kg (lbs) Engine Main Data No. of Cylinders Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

195 324.2 (85.7) 2405 (94.7) 1390 (54.7) 1795 (70.7) 6190 (13646) 6630 (14616) 12 165/190 (6.5/7.5) 4.06 (248) 48.7 (2978)

203 366.9 (96.9) 2405 (94.7) 1390 (54.7) 1795 (70.7) 6190 (13646) 6630 (14616) 12 165/190 (6.5/7.5) 4.06 (248) 48.7 (2978)

206 409.5 (108.2) 2405 (94.7) 1390 (54.7) 1795 (70.7) 6190 (13646) 6630 (14616) 12 165/190 (6.5/7.5) 4.06 (248) 48.7 (2978)

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Push-pull/Loco.

Engines
for push-pull trains and locomotives

1500 kW 1800 kW

Dimensions and Masses: Engines with standard equipment

> Well differentiated choice of engines spanning wide range of power outputs > High power-to-weight ratios for lightweight trains > Meeting emissions regulations EU Stage IIIB Engine Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power 12V4000R64 1500 1800 EU IIIB/UIC IIIA 205 370.5 (97.9) 2670 (105.1) 1696 (66.8) 2001 (78.8) 7600 (16754) 8130 (17923) 12 170/210 (6.7/8.3) 4.77 (291) 57.2 (3491) 12V4000R84 1800 1800 EU IIIB/UIC IIIA 205 444.6 (117.5) 2670 (105.1) 1696 (66.8) 2001 (78.8) 7600 (16754) 8130 (17923) 12 170/210 (6.7/8.3) 4.77 (291) 57.2 (3491)

kW rpm

g/kWh l/h (gal/h) Engine Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) Mass, dry kg (lbs) Mass, wet kg (lbs) Engine Main Data No. of Cylinders Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

Series 4000-04 engines portfolio meeting EU Stage IIIB/UIC IIIA will be completed with 8V/ 20V models. For further information please contact your MTU distributor.

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Push-pull/Loco.

Engines
for push-pull trains and locomotives

1700 kW 2400 kW

Dimensions and Masses: Engines with standard equipment

> Cutting-edge technology with built-in potential > Uniquely low emissions and consumption > Market leader in its class for European diesel locomotives Engine Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power 16V4000R41R 1700 1500 UIC II 16V4000R41 2000 1800 UIC II 16V4000R41L 2200 1860 UIC II 16V4000R43R 2000 1800 EU IIIA compl./ UIC IIIA 207 498.8 (131.8) 2865 (112.8) 1562 (61.5) 2015 (79.3) 8175 (18023) 8770 (19334) 16 170/210 (6.7/8.3) 4.77 (291) 76.3 (4656) 16V4000R43 2200 1800 EU IIIA compl./ UIC IIIA 206 546.0 (144.3) 2865 (112.8) 1562 (61.5) 2015 (79.3) 8175 (18023) 8770 (19334) 16 170/210 (6.7/8.3) 4.77 (291) 76.3 (4656) 16V4000R43L 2400 1800 EU IIIA compl./ UIC IIIA 207 598.6 (158.1) 2865 (112.8) 1562 (61.5) 2015 (79.3) 8175 (18023) 8770 (19334) 16 170/210 (6.7/8.3) 4.77 (291) 76.3 (4656)

kW rpm

g/kWh l/h (gal/h) Engine Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) Mass, dry kg (lbs) Mass, wet kg (lbs) Engine Main Data No. of Cylinders Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

198 405.5 (107.1) 2875 (113.2) 1405 (55.3) 1815 (71.5) 7400 (16314) 7880 (17373) 16 165/190 (6.5/7.5) 4.06 (248) 65 (3967)

202 486.7 (128.6) 2875 (113.2) 1405 (55.3) 1815 (71.5) 7400 (16314) 7880 (17373) 16 165/190 (6.5/7.5) 4.06 (248) 65 (3967)

206 546.0 (144.3) 2875 (113.2) 1405 (55.3) 1815 (71.5) 7400 (16314) 7880 (17373) 16 165/190 (6.5/7.5) 4.06 (248) 65 (3967)

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Push-pull/Loco.

Engines
for push-pull trains and locomotives

2000 kW 2400 kW

Dimensions and Masses: Engines with standard equipment

> Cutting-edge technology with built-in potential > Uniquely low emissions and low consumption > Meeting emissions regulations EU Stage IIIB Engine Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power 16V4000R64 2000 1800 EU IIIB/UIC IIIA 205 493.3 (130.3) 3140 (123.6) 1696 (66.8) 2001 (78.8) 9200 (20282) 9773 (21546) 16 170/210 (6.7/8.3) 4.77 (291) 76.3 (4666) 16V4000R74 2200 1800 EU IIIB/UIC IIIA 205 543.4 (143.6) 3140 (123.6) 1696 (66.8) 2001 (78.8) 9200 (20282) 9773 (21546) 16 170/210 (6.7/8.3) 4.77 (291) 76.3 (4666) 16V4000R84 2400 1800 EU IIIB/UIC IIIA 205 592.8 (156.6) 3140 (123.6) 1696 (66.8) 2001 (78.8) 9200 (20282) 9773 (21546) 16 170/210 (6.7/8.3) 4.77 (291) 76.3 (4666)

kW rpm

g/kWh l/h (gal/h) Engine Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) Mass, dry kg (lbs) Mass, wet kg (lbs) Engine Main Data No. of Cylinders Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

Series 4000-04 engines portfolio meeting EU Stage IIIB/UIC IIIA will be completed with 8V/ 20V models. For further information please contact your MTU distributor.

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Push-pull/Loco.

Engines
for push-pull trains and locomotives

2700 kW 3150 kW

Dimensions and Masses: Engines with standard equipment

> Outstanding power density. Unbeaten power-to-weight ratio > Worlds most powerful locomotive diesel engine in its class > Up to 3,150 kW for 4-axle locomotives and 6-axle locomotives Engine Model Rated Power Speed Exhaust Emissions Fuel Consumption at Rated Power 20V4000R43 2700 1800 EU IIIA compl./ UIC IIIA 208 676.6 (178.8) 3335 (131.5) 1562 (61.5) 2015 (79.3) 9850 (21716) 10520 (23193) 20 170/210 (6.7/8.3) 4.77 (291) 95.4 (5822) 20V4000R43L 3000 1800 EU IIIA compl./ UIC IIIA 210 759.0 (200.5) 3335 (131.5) 1562 (61.5) 2015 (79.3) 9850 (21716) 10520 (23193) 20 170/210 (6.7/8.3) 4.77 (291) 95.4 (5822) 20V4000R53 3150 1800 EU IIIA compl./ UIC IIIA
On request, please contact your mtu dealer

kW rpm

g/kWh l/h (gal/h) Engine Dimensions and Masses Length (L) mm (in) Width (W) mm (in) Height (H) mm (in) Mass, dry kg (lbs) Mass, wet kg (lbs) Engine Main Data No. of Cylinders Bore / Stroke mm (in) Displacement/cyl. Displacement, total l (cu in) l (cu in)

3335 (131.5) 1562 (61.5) 2015 (79.3) 9850 (21716) 10520 (23193) 20 170/210 (6.7/8.3) 4.77 (291) 95.4 (5822)

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Push-pull/Loco.

References
Diesel engines and PowerPacks in railcars/ push-pull trains and locomotives High-Speed-Trains and Locomotives Railcars

Deutsche Bahn V290 1 x 1000 kW

Alstom Lint 41 PowerPack 2 x 390 kW

Bombardier Traxx 1 x 2200 kW

Bombardier Turbo Star PowerPack 2 x 390 kW

Siemens ER 20D EURORUNNER 1 x 2000 kW

Siemens Desiro Classic 2 x 335 kW

Vossloh Mak 2000-4 1 x 2700 kW

Metrowagonmash RA 1 2 x 360 kW

Siemens/Alstom BB 475000 1 x 2000 kW

PESA SA 103 2 x 315 kW

Siemens

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References

References
Diesel engines and PowerPacks for special-purpose rail vehicles

> Individual traction system solutions > Flexibility in design and installation

> Emissions optimized engines for tunnel operations with particle lter/ exhaust catalyst

Remotecontrolled shunter

Rotary Snow-Plow

Fire Fighting and Rescue Train

Auxiliary locomotive for tunnel operations

Grinding train

Railroad inspection vehicle

Track layer

Rail crane
Further appplications with MTU system solutions are e.g.: - Locomotives for underground railways - Mountain railways

Overhead line inspection railcar

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References

Repowering
with MTU Diesel engines

For economical reasons, many railway companies and locomotive operators have decided to repower older locomotives and rail cars which are in good general condition with modern diesel engines. Due to their high technical standards, MTU engines fulll all technical criteria for repowering projects: > > > > Economical alternative to new procurement Reduced investment costs Increased availability equal to that of a new vehicle Individual solutions to suit existing system interfaces

MTU is your competent partner for a successful repowering project, we offer everything you require: > Active support provided by a professional engineering service during all phases of a repowering project > Design and realisation of the traction plant > Engines adaptable to existing parameters > Reliable and sturdy engines with low fuel and lube oil consumption rates > Long maintenance intervals and low life-cycle costs > Compact dimensions for troublefree installation in existing engine rooms > Low installation and maintenance effort > The accessories incorporate clearly dened interfaces and are mounted to the engine in such a manner as to be easily accessible for maintenance operations > Good power-to-weight ratios permit installation of higher power ratings without exceeding permissible axle loads > Qualied support by the MTU Product Support organisation > Meet all applicable exhaust gas and noise emissions limit values

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Repowering

Automation
powerline for Series 4000

powerline MTUs automation system for train drive units represents a step into a whole new future of technology for rail vehicles. Even with only the basic components ADEC, POM and PAU, the powerline automation system makes the integration of the engine into the locomotive a simple process. POM, like ADEC, is an electronic module mounted permanently to the engine. Control, regulation and monitoring are all part of the package that MTU delivers. With the help of optimized interface technology, the engine is quick and easy to install. MDEC / ADEC engine control systems The engine control systems MDEC (MTU Diesel Engine Control) for Series 4000 R41 ADEC (Advanced Diesel Engine Control) for Series 4000 R43/R04 are systems that have been developed and produced by MTU specically for use with the very latest high-performance diesel engine technology designed not only for full control of the Common Rail technology in the Series 4000, but above all for the management of frequent extreme loads and sudden load changes, which can be overcome effortlessly and smoothly using this system. The most important features at a glance: Component mounted on and wired into the engine Integrated control and monitoring system Fuel-optimized output regulation Integrated safety and self-test system Data bus interface
ADEC - Engine Management

POM (Power Output Module) for Series 4000 R43/R04 Module with actuating function for the starter motor and alternator, with the following features: Component mounted on the engine Starter relay and other conventional power routing not required Optimization of start-up process; starter motor monitoring with engaging function Alternator function monitoring Line break and short circuit monitoring Battery voltage monitoring with start-up intervention plus status indication and error report function ADEC and POM linked via CAN data bus Fully automated start-up control with ADEC

POM - Engine Management

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Automation

Automation
powerline for Series 4000

powerline for new locomotives or repowering with Series 4000 R41/R43/ R04 PAU Engine (Power Automation Unit) Module for the monitoring, control and system integration of peripheral engine components, with the following features: Stand-alone component with (redundant) CAN open interface to vehicle control system Transfer of all engine-related operational data including diagnostics to the vehicle control system Additional monitoring and control of peripheral engine systems Coolant level monitoring Fuel pump actuation Air lter monitoring Integrated safety functions Data output for fuel consumption indicator Ethernet diagnosis interface (e.g. service laptop) Fault ring buffer Cooling fan regulation

powerline additional module for repowering of diesel-electric locomotive drive systems PAU Traction (Power Automation Unit) Module for the monitoring, control, regulation and system integration of the traction generator and rectier, with the following features: For drive systems with direct-current series-wound engines Optimized output regulation, congured for the diesel engine Generator, rectier and vehicle engine monitoring Field weakening control for vehicle engine Wheel-slip protection Integrated safety functions (e.g. power shut-off) Ethernet interface (e.g. service laptop) Fault ring buffer Locomotive safety functions Specication includes current and voltage transformers plus amplier for generator excitation

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Automation

PAU - Engine

PAU - Traction

Automation
powerline for Series 4000
ADEC = Advanced Diesel Engine Control MDEC = MTU Diesel Engine Control PAU = Power Automation Unit POM = Power Output Module

MTU powerline PAU Engine for new locomotives or repowering with Series 4000 R41/R43/R04

MTU powerline PAU Traction for repowering of diesel-electric locomotives

Cab

Vehicle control system

PAU Engine

+
ADEC

PAU Traction

Series 4000 R41 MDEC

Series 4000 R43/R04 MTU amplier Generator excitation

Starter motor Alternator

POM

Starter motor Alternator

24V battery or MTU CaPoS starter system

Peripheral engine components Fuel pump Cooling fan Coolant level switch

24V battery or MTU CaPoS starter system Example for Engine Series 4000

38 I Rail I Sales Program 2012

Sales Program 2012 I Rail I 39

Automation

MTU Voltage transformer + current transformer

Traction generator

Automation
CaPoS Capacitor Power System for Series 1600, 1800, 4000
Example for Engine Series 4000

Innovation right from the start. CaPoS is an innovative UltraCap voltage supply system which obviates the need for conventional starter batteries in railroad applications. CaPoS uses capacitor technology to optimize startup behavior. The number of UltraCap modules to be used depends on the type of engine involved and its breakaway torque. CaPoS may be used autonomously or in conjunction with the powerline automation system. The most important features at a glance: Autonomous and modular construction Maintenance-free system Signicant reductions in weight and volume compared with conventional starter batteries Optimized cold-starting properties Low life-cycle costs No voltage interruption during start-up On-board voltage of 16V 154V possible Integrated self-monitoring system with interface to vehicle control system

CaPoS for new locomotives or repowering

Cab

Vehicle control system

Series 4000 R41

Series 4000 R43/R04

MDEC

ADEC

Starter motor

POM

Starter motor

Voltage transformer (DC/DC)

UltraCap module 1
Loksteuerung

UltraCap module 5

Depending on engine, use of between 1 to 5 UltraCap modules

On-Board battery

40 I Rail I Sales Program 2012

Sales Program 2012 I Rail I 41

Automation

CaPoS for the 12V4000

CaPoS

Automation
PowerPack
SAM = Service Application Module

The PowerPack Automation system is an innovative high-end technology of MTU for rail vehicles e.g. for rail cars. PowerPack Automation optimizes the control, regulation and monitoring of the entire drive system. Representing a modular system, it ensures perfect adaptation of the drive system to the most complex operating conditions in rail applications. PowerPack Automation allows: > Easy integration in new or in case of retrots existing vehicle control systems > Flexible adaptation to the vehicle or its components and to project-specic requirements > Automatic power adjustment or, if required, engine shutdown by the integrated safety system as well as all other required monitoring and safety functions > Traction optimization by the integrated load management (torque control) feature depending on the consumers connected (e.g. generator, compressor etc.) Thus, the new PowerPack generation provides > High power efciency > Lowest fuel consumption > Minimum exhaust emissions which are considerably below the statutory requirements (e.g. currently valid EU Stage IIIA and future EU Stage IIIB) > Flexible and standardized interface solutions Diagnosis and maintenance > Interface to the central railcar computer system, including the drive system components.
System highlights and benets > Complete system supplied from one single source > Modular design > Optimized diagnostic function SAM > Intelligent CAN bus technology > Fast project implementation > Easy integration SAM

PowerPack auxiliary PTOs

Engine controller

Gearbox control system

Reversing control system

Braking control system

Vehicle control system

42 I Rail I Sales Program 2012

Sales Program 2012 I Rail I 43

Automation

MTU ValueCare
A valuable portfolio of products and services

Getting the most out of your MTU engines and systems is of paramount importance. Thats why we offer MTU ValueCare, a complete portfolio of products and services designed to help maximize both performance and uptime. The MTU ValueCare portfolio includes global support and service products through ValueService; genuine spare parts and top quality consumables through ValueSpares; and remanufactured engines and service parts through ValueExchange. No matter where you are or what you need, were always ready to provide valuable support through our worldwide MTU service network. ValueService Products: Remote Services Identifying faults early, before they turn into unwanted complications, saves valuable service time and helps you make quick operational decisions. As a part of ValueService, Remote Services is a powerful diagnostic solution that links you directly to a record of the activity of your MTU engines and systems through a secure Internet connection. A telemetric device within Remote Services stores selected information and transmits it in real time or at predetermined intervals. Important engine data such as oil temperature, current location and operating hours can be conveniently retrieved for analysis, even remotely from a far-away work site. All you need is a computer with an Internet connection. Remote Services can be ordered as an option on an MTU engine. If you already have an MTU engine, Remote Services is also available as a retrot. The minimum duration for a Remote Services User Agreement is 2 years, after which time its automatically extended for 6 months. Maintenance Solutions: > Customized Care: professional, planned maintenance solutions from MTU > Extended Coverage: providing coverage beyond your standard warranty on your MTU engines and systems > Annual Check: a yearly professional inspection of your MTU engines and systems by MTU experts
44 I Rail I Sales Program 2012

In addition, we can provide further value-added services: > Technical documentation > Training > RAMS - LCC-Analysis ValueSpares: > Genuine parts > Top quality consumables (lubricants, coolants, lters) ValueExchange: > Remanufactured Parts > Remanufactured Engines > Remanufactured PowerPacks > Engine Overhaul

Sales Program 2012 I Rail I 45

After Sales

Exhaust emissions

UIC (International Railway Association) In its codex 624V the UIC has established emission limits for rail traction engines, which are binding for all its members. It is expected that in future the limits will be adjusted to the rail limits of the EU nonroad directive (see below).
Stage UIC II Power Pn Speed nn Pn 560 kW Pn 560 kW nn 1000 rpm Pn 560 kW nn 1000 rpm NOx g/kWh 6.0 9.5 9.9 HC g/kWh 0.6 0.8 0.8 CO g/kWh 2.5 3.0 3.0 Partic. g/kWh 0.25 0.25 0.25 Date 2003 2003 2003

Railcar engines
Stage Power Pn Speed nn > 130 kW > 130 kW NOx+HC NOx g/kWh 4.0 2.0 CO HC g/kWh 4.0 0.19 g/kWh 3.5 3.5 Partic. g/kWh 0.2 0.025 Date*

IIIA IIIB

2006 2012

* Date for placing the engines on the market, type approval one year earlier

> > > >

No Stage I and II Test cycle: ISO 8178-4, C1 (railcars) resp. F (locomotives) Test condition: 25C air temp. Compliance with the limits must be proved over the useful life span of the engine

> Test cycle: ISO 8178-4, F > Test condition: 25C air temp. UIC IIIA: > Test cycle: ISO 8178-4, F for locomotives, C for railcars > The UIC Stage IIIA corresponds to the Stage IIIA of the EU-Nonroad-Directive 97/68/EC (see below) > Test fuel corresponding to ISO 8178-5 > Test condition: air temperature 25C EU - Nonroad Directive 97/68/EC (as amended by 2010/26/EC) Locomotive engines
Stage Power Pn Cyl. displac. 130 - 560 kW > 560 kW > 2000 kW Vh,z > 5 l > 130 kW NOx+HC NOx g/kWh 4.0 6.0 7.4 4.0 CO HC g/kWh 4.0 0.5 0.4 4.0 g/kWh 3.5 3.5 3.5 3.5 Partic. g/kWh 0.2 0.25 0.2 0.025 Date*

USA - EPA Rail Regulation 40 CFR 92 Emission limits for locomotives with an engine power above 750 kW
NOx HC CO Partic. g/kWh g/kWh g/kWh g/kWh Tier 1 (as of 2002) 9.9 0.74 2.9 0.60 14.7 1.61 3.3 0.72 Smoke (opacity) station. 30s 3s 0.25 0.25 0.4 0.4 0.5 0.5

Line-haul cycle Switch cycle Line-haul cycle Switch cycle

Tier 2 (as of 2005) 7.4 0.40 2.0 10.9 0.8 3.2

0.27 0.32

0.2 0.2

0.4 0.4

0.5 0.5

IIIA

2007 2009 2009 2012

IIIB

* Date for placing the engines on the market, type approval one year earlier

46 I Rail I Sales Program 2012

> Engines below 750 kW must comply with the nonroad-regulation (40 CFR 89 resp. 40 CFR 1039) > Test cycle: US locomotive cycle > Test conditions: air temp. 7 - 41C, ambient pressure 0.88 - 1.05 bar > Compliance with the limits must be guaranteed over the useful life period of the engine > The opacity is measured during the transitions from one notch to the next > ABT (Averaging, Banking and Trading) of emission credits is allowed

Sales Program 2012 I Rail I 47

Emissions

USA - EPA Nonroad Regulation 40 CFR 89, 40 CFR 1039

Diesel engines Power Pn kW Tier 1 Pn > 560 Tier 2 19 Pn < 37 37 Pn < 75 75 Pn < 130 130 Pn 225 225 Pn 450 450 Pn 560 Pn > 560 Tier 3 19 Pn < 37 37 Pn < 75 75 Pn < 130 130 Pn 560 Pn > 560 Tier 4 interim 19 Pn < 37 37 Pn < 56 56 Pn < 130 130 Pn 560 Pn > 560 Tier 4 interim Pn > 900 Tier 4 19 Pn < 37 37 Pn < 56 56 Pn < 130 130 Pn 560 Pn > 560 Tier 4 - Genset Pn > 560 NOx HC g/kWh g/kWh NOx + NMHC 9.2 7.5 7.5 6.6 6.6 6.4 6.4 6.4 1.3 7.5 7.5 6.6 6.6 6.4 6.4 6.4 CO g/kWh Particul. g/kWh as of MY*

11.4 5.5 5.0 5.0 3.5 3.5 3.5 3.5

0.54 0.6 0.4 0.3 0.2 0.2 0.2 0.2

2000 2004 2004 2003 2003 2001 2002 2006

no further reduction 4.7 4.7 4.0 4.0 4.0 4.0 no further reduction 7.5 4.7 3.4 2.0 3.5 Genset 0.67 4.7 4.7 0.4 0.4 3.5 0.67 7.5 4.7 0.19 0.19 0.4 0.4 4.7 4.7 0.19 0.19 0.19 0.19

5.0 5.0 3.5

0.4 0.3 0.2

2008 2007 2006

> In addition to the particulate measurement, a transient smoke test is required (see chapter 6); as of Tier 4 this applies to engines with particulate emissions above 0.07 g/kWh only; engines which operated at constant speed are generally excluded > Stationary test cycle: ISO 8178-4, C1/D2/E3; as of Tier 4, the appropriate Ramped Mode Cycle may be used alternatively (see chapter 6) > Transient test cycle: NRTC; all engines as of Tier 4, except engines above 560 kW and constant speed engines of any power category > Test condition: 25C air temp., as of Tier 4: 20C - 30C air temp., ambient pressure 0.8 - 1.03 bar > Compliance with the limits must be guarabteed over the useful life period of the engine > ABT (Averaging, Banking and Trading) of emission credits is allowed > NTE (Not To Exceed) effective dates: 2011 for engines > 130 kW, 2012 for engines 56 - 160 kW, 2013 for engines < 56 kW. NTE limits are set 1.25 to 1.5 times the cycle limit. NTE limits apply at time of certication throughout the useful life of the engine.

5.5 5.0 5.0 3.5 3.5 3.5 5.5 5.0 5.0 3.5 3.5 3.5

0.3 0.03 0.02 0.02 0.1 0.1 0.03 0.03 0.02 0.02 0.04 0.03

2008 2012 2012 2011 2011 2011 2013 2013 2014 2014 2015 2015
Sales Program 2012 I Rail I 49

* Optional for Tier 3/4: 37-56 kW - PM = 0.3 g/kWh as of 2008; 56-560 kW.- Phase in/Phase out 48 I Rail I Sales Program 2012

Emissions

Contents

Exhaust emissions

Conversion Table

Notes

1 kW = 1.360 PS 1 kW = 1.341 bhp 1 bhp = 1.014 PS 1 oz = 28.35 g 1 lb = 453.59 g 1 short ton = 907.18 kg 1 lb/bhp = 447.3 g/PSh 1 lb/bhp = 608.3 g/kWh 1 gal/bhp(US) = 4264 g/kWh 1 kWh = 860 kcal 1 cal = 4.187 J 1 BTU 1 inch 1 sq. inch 1 cu. inch 1 foot 1 sq. foot 1 mile 1 naut. mile 1 UK Gallon 1 US Gallon 1 US Barrel = 1.055 kJ = 2.540 cm = 6.542 cm2 = 16.387 cm3 = 3.048 dm = 9.290 dm2 = 1.609 km = 1.853 km = 4.546 l = 3.785 l = 0.159 m3 = 42 US Gallons

g e 1 lb 1 short ton 1 ft lb 1 ft/min pDiesel 1 lb/sqin 1 mm Hg

= 9.80665 m/s2 = 3.14159 = 2.71828 = = = = = = = 16 oz 2000 lbs 1.356 Nm 0.00508 m/s 0.85 kg/l 0.069 bar (1 psi) 1.333 mbar (133.3 Pa) 0.0981 mbar (9.81 Pa) t (C) + 273.15 5/9 x (t (F) -32) 5/4 x t (R) 12 inches 3 feet 5280 feet 6080 feet

1 mm H2O = T (K) t (C) t (C) 1 foot 1 yard 1 mile 1 naut. mile = = = = = = =

Energy: Power: Force: Pressure: MEP (bar) Torque (Nm)

1 J = 1 Ws = 1 VAs = 1 Nm 1 W = 1 VA = 1 Nm/s 1 N = 1 kgm/s2 1 Pa = 1 N/m2 (1 bar = 105 Pa) = Pcyl(kW) x 1200 n(1/min) x Vcyl(l) = Pges(kW) x 30000 n(1/min) x

Further special sales programs: Marine PowerGen Industrial, stationary C&I, Agricultural, Mining Oil & Gas Onsite Energy
Sales Program 2012 I Rail I 51

50 I Rail I Sales Program 2012

A TOGNUM GROUP BRAND

Europe I Middle East I Africa MTU Friedrichshafen GmbH, 88040 Friedrichshafen, Germany P +49 7541 90 7004, F +49 7541 90 7084 rail1@mtu-online.com, www.mtu-online.com Asia I Australia I Pacic I Tognum Asia Pte. Ltd., 1 Benoi Place, Singapore 629923, Republic of Singapore P +65 6861 5922, F +65 6861 3615 rail2@mtu-online.com, www.mtu-online.com USA I Canada I Mexico I Latin America I Tognum America Inc., 13400 Outer Drive West, Detroit, Michigan 48239, USA P +1 313 592 7000, F +1 313 592 3883 rail3@mtu-online.com, www.mtu-online.com

Subject to change. | 319016101 | 1/12 | VMC 2012-02 B | Printed in Germany on chlorine-free bleached paper.