InnoTrans 2004: mtu Gets Large Orders for 4000 Series and Stage 3A PowerPack

• 400 Power Modules with BR 4000 for French locomotives
• World’s most powerful rail engine with a particulate trap installed in Vossloh locomotives
• 70 PowerPacks for power cars in Denmark
• Overhaul for PowerPacks

MTU Friedrichshafen was appearing at Innotrans, the Berlin Rail Convention, with larger orders from France and Denmark for the 4000 series and the Euro-3 Powerpack. The sales success in this segment is largely due to the fact that both products are equipped with state-of-the-art drive technology for locomotives and power cars. The 4000 engine series is available for use in diesel locomotives with 8, 12 and 16 cylinder engines. The 20V 4000 with 3000 kW output (according to UIC) is the most powerful rail engine in its class. The new generation of the Stage 3A PowerPack® is the power unit for power cars with the lowest emissions world-wide. The core of this unit is a type 6H 1800 engine with performance of up to 360 kW.

4000 success series on track

The 4000 engines series has acquired an outstanding reputation as a prime example of state-of-the-art drive technology in new locomotives and for repowering projects. Fitted with common rail injection technology and electronic engine management, the 4000 series combines high performance with economy and low emissions. So far 1,150 engines of this series have been ordered for rail vehicles. 4000 engines are now being used by over 25 rail operators in Europe and Asia.

Large order from France: 400 Power Modules for French 475000 locomotives

A large order from the SNCF, the French railways company, is one of the recent successes achieved by mtu with the Power Module. For powering 400 heavy-duty diesel-electric locomotives of the 475000 series, the company is supplying the required Power Modules. It consists of one 16V 4000 motor and a three-phase generator. The first locomotives are expected to be in operation from 2006.

A further large order from SNCF relates to a repowering project where 52 multipurpose BB66000 locomotives are each to be equipped with a 12V 4000. The engine, which achieves a performance of 1,040 kW at 1,550 min -1, is replacing the 16 cylinder engine SACM-MGO previously installed. In March 2004 the first repowered locomotives were presented. There is a further option for repowering up to 300 locomotives.

World’s most powerful rail engine with a particulate trap installed in Vossloh locomotives

On July 7, 2004 the Kiel-based locomotive manufacturer Vossloh Locomotives GmbH installed the first 20V 4000 rail engine in the new Mak 2000. In comparison to its predecessor, the G 2000 BB, the locomotive with the 2700 kW engine increases performance by 20%.

The train manufacturer Vossloh has so far produced two locomotive prototypes, which will undergo intensive testing in the coming months. One of these is a highlight Vossloh is presenting to the public at Innotrans 2004 as the first train of the new series. The other, the so-called “Nordlok”, will be taken on a number of test drives in winter conditions.

A particular trap filter system, unique in its power category, by the Swiss company HUG has been installed in the trade fair train. The separation efficiency is at above 95% without impinging on engine or locomotive performance. Due to space constraints the Vossloh particular trap filter was integrated into the roof of the vehicle frame. The filter in question has a regeneration unit. This means that particulate caught in the filter is burnt off after a certain amount of time. The use of particulate traps in locomotives is not anything fundamentally new for mtu. Since 1999 particulate filters have been in use in three BVG Berlin vehicles equipped with series 183 engines. Further examples are vehicles of the Swiss company Scheuchzer with the 12V 4000 as well as SBB with 8V.

Moreover mtu is supplying each is 29 MaK 1000 series diesel hydraulic locomotives with an 8V 4000 engine with 1,100 kW performance. These locomotives are also designed for Europe-wide and thus cross-border use. Mak is already authorized for use in many European countries. Its service profile is characterized by flexibility and versatility. Thus the 4-axle, 80-ton standard locomotive can either be employed as a shunter or for routed passenger transport.

The Siemens Transportation Systems ER 20 on the international rail markets

The diesel electric routed passenger locomotive ER 20 ("EuroRunner 20“) by Siemens Transportation Systems already aroused world-wide interest amongst rail operators shortly after its market launch in 2002. For the drive of the ER 20, also known as the "whisper train" because of its low sound emissions, mtu supplies the Power Module drive packet with a 2,000 kW strong 16V 4000 engine and a three-phase generator. The locomotive celebrated its launch in spring 2002 with Austrian Rail (ÖBB) as series Rh 2016, using the name "Hercules". As part of the largest modernization program at ÖBB, it facilitates the railway company’s entry into the liberalized European railway markets and is deployed on the ancillary network and in cross-border traffic between Austria, Germany, the Czech Republic, Slovenia and Hungary. Siemens designed the ER 20 is such a way that it can meet various national requirements.

And in the south of Germany, type ER 20 locomotives are now also in use. Since December 2003, the Swiss company Thurbo AG has been operating between Munich and Oberstdorf with 5 commuter trains under the name "Allgäu-Express“ on behalf of Regentalbahn/Vogtlandbahn. Besides the design of the ER 20 for commuter transportation, the first five versions for goods transport are already in use. The first trains of this kind were obtained by the Preßnitztalbahn in Germany as well as by Steiermärkischen local rail in Graz. The good reputation of the ER 20 has reached as far as Hong Kong. Five ER 20 locomotives are being used there by the Kowloon Canton Railways Corporation (KCRC).

8V 4000 engine for the cleanest shunter locomotive in the world

Since fall 2002 German Rail has been modernizing its most important shunter train. 398 vehicles in total, which pull up to 2000 ton trains, are being repowered with a 1000 kW strong 8V 4000. This engine is in conformity with the emission guidelines valid until 2008. With the V290 a locomotive is now on the tracks that points the way for diesel powered rail traffic as a whole.

70 Euro 3 PowerPacks© for power cars in Denmark

Since 2002 the mtu has been providing the Euro-3-PowerPack with the new 6H 1800 engine. The new engine has a performance of up to 350 kW and satisfies Euro 3 emission standards. Starting this year, the new PowerPacks© are being tested in Denmark in a Siemens AG Desiro and in a Lint train from the Salzgitter-based company ALSTOM LHB GmbH – so far to the complete satisfaction of the customers. Meanwhile the Danish rail operator Arriva put in an order for over 70 PowerPacks© which have already been delivered in full. The company has also had a lot of success in recent years with the so-called PowerPack©, compact drive units for power cars. PowerPacks© are complete drive systems, which include further components besides the engine such as gears, cooling, filter systems which are installed sub-floor. In 1997 mtu was the first supplier of these worldwide. Since then the PowerPack© has turned into a best-seller. More than 3000 units have been ordered to date. mtu is exhibiting 3 PowerPack© in a steel tower at its trade fair stand. Each of the drive modules is intended for a different power car vehicle.

Particulate filter for PowerPack©

With an eye to stricter emission guidelines mtu is providing particulate traps not only for series 4000 locomotive engines but also for PowerPack© which can be retrofitted in the vehicle. These are combined silencers with particulate trap.

Overhaul for PowerPack©

Since the beginning of the year mtu has been offering a comprehensive and yet very streamlined overhaul for PowerPack©. In this procedure, which is usually carried out after 18,000 operating hours, wearing parts are replaced at company headquarters in Friedrichshafen according to the Reman principle (=remanufacturing, refurbishing) either with refurbished or new parts. The end result is a drive module that is as good as new. The real advantages of this procedure are to be sought in the very short overhaul time of no more than 10 working days, a very clearly calculated fixed price that is very advantageous to the customer, the refurbishing of supplier parts by the original manufacturer, mtu's outstanding technical infrastructure, including state-of-the-art test bays, and mtu’s guarantee that all components including the engine are at the most up-to-date technological level. Customer response has been totally positive. By now all well-known rail operators in Germany have taken up this service offer.