YOUR BEST INVESTMENT IN RAILCAR GENERATOR SYSTEMS - PREDICTABLE QUALITY, PERFORMANCE AND SERVICE LIFE.Design objectives were:
Prime mover is Deutz FM type liquid cooled direct injection diesel engine. This news series of emissions engines are brand new from the ground up, designed with leading edge technology throughout to meet proposed worldwide emissions legislation. Exceptionally low exhaust emissions and low noise levels are the hallmarks of this new family of Deutz engines. The future oriented high pressure fuel injection system and combustion concepts include massive individual injection pumps, precise fuel tiring and low swirl combustion process. All engines are able to meet present and future U.S. industrial and European emission regulations, with extremely low fuel consumption and with lower than average engine noise levels. Engine levels are 4 decibels below the quietest rival. M/D units will operate satisfactorily on both #2D Red Diesel fuel, without injector fouling.
The generator is a new type which delivers improved efficiency in a smaller package. Manufactured by the worlds best recognized builder; now produced here in the USA.
Wherever possible engine accessories and components are mounted off the engine to eliminate the destructive effects of engine vibrations on operating systems and accessories.
Dual fuel filter system provides an additional measure of protection to trap water and contaminants which could otherwise damage the fuel injection system.
The cold weather starting systems are the latest state of the art, with sealed heat bulbs located directly in the combustion chamber where auxiliary heating is safest and most effective. The systems operate with 12V. current and are self contained.
Cooling air intake area located entirely on Service side, toward platform.- draws coolest available air in the gen set environment. Simplifies installation on skirting-equipped railcars. Strategic location of air intake panel also reduces to minimum the ingestion of road dust and dirt. All models are equipped with cleanable media filters for cooling air stream serviceable from the outside.
Main frame houses all engine/generator operating systems inboard for maximum reliability and protection from vibration and damage.
ENGINES: Deutz liquid cooled diesel engines, specific engine per unit as shown.
Deutz diesels are premium quality engines which include these long-life feature: Cam shaft forged steel alloy Connecting rods-forged steel alloy. Camshaft-forged steel alloy. Cylinder head-replaceable valve seats and valve guides. Fuel system-ultra reliable Bosch type in-line multi-plunger injection pump or individual injection pumps. Lube system-gear oil pump and individual jets for oil cooling the pistons. Lube oil cooler Pistons-aluminum alloy.
FUEL SYSTEM: Primary water separator fuel filter and secondary fine fuel filter. Bulkhead fuel supply connections located on outside rear of unit. 12V. operated fuel solenoid provides instant engine shutdown capability. Wire reinforced fuel supply hoses.
COLD STARTING SYSTEM: 12V. sealed pintle type heaters direct in combustion chambers.
AIR CLEANER: Dry type dual element air cleaner with self-cleaning precleaner, low restrictions for improved fuel economy and extended service interval. Filter service indicator included. Rotary type centrifugal precleaners extend main air filters cartridge life.
EXHAUST SYSTEM: Turbo exhaust manifold and tailpipe wrapped with removable insulation blankets to reduce radiator heat saturation.
RADIATOR: Specially designed radiator with 5-row core and brazed support frame for extra vibration resistance. Rated for safe operation at rated temperatures and climatic conditions. Elastomeric mounts provide double isolation from engine vibration and single isolation from road vibration and main frame stresses.
BATTERY: None included. Steel battery enclosure mounted to unit end panel. Removable. Battery cables included.
COOLING SYSTEM: Positive forced ventilation of engine/generator compartment with positive ambient temperature air supply to both engine and generator cooling systems. Cooling air flows straight through enclosure. Cooling air inlet separated as far as possible from hot air outlet to reduce potential for heat recirculation. Cleanable foam media filter reduces accumulation of air-bourne dirt and debris inside the enclosure.
LUBE OIL LEVEL SENSOR: Mounted directly in oil pan at minimum safe oil level (12V. contactor).
LUBE OIL FILL & DIPSTICK: Located directly inside service access doors.
CAUTIONARY DECALS: Danger/Caution decals applied in all locations deemed as potentially dangerous.
GENERATOR: Totally brushless revolving field alternator built in the USA. High temp Class H insulation throughout for continuous duty at 105 Deg. C temp rise. Solid state type voltage regulation system with adjustable voltage output and voltage ramp-down. Voltage regulator is thermally load protected. 12-Lead reconnectable wiring configuration. Voltage regulation = +/- 1.5% at constant speed. Voltage adjustment = +/- 10%. Adjustable Volts-per-Hertz voltage ramp-down feature for motor protection. Frequency regulation = 3% from no load to full load. High efficiency performance for maximum fuel economy
AC LOAD WIRING: Unit wiring is Polyrad 60OV, Amtrak Spec #323 approved, irradiated Polyolefin insulation. Wired to terminal posts located in main power distribution box located on rear side of unit.
AC EQUIPMENT PROTECTION: Special inboard enclosure box, accessible from service side, protects voltage regulator and AC gear from dirt and moisture.
WIRE SAFETY: Poly-Rad wiring and noncombustible fiberglass wire loom.
Primary fuel filter (with drain) located outside enclosure.
Fuel supply hoses are wire reinforced to provide fire resistance and prevent failures due to chafing, cutting or pinching. Fire detection devices with engine shut down protection, on Model 5-65DE & up.
Enclosure panels are constructed of solid sheet steel, insulated with heavy multilayer high performance composite sound insulation material to absorb mechanical sounds and engine air intake sounds. All panels facing toward railcar are totally solid (without openings) for improved noise control. No straight-through paths for sound emissions through top or sides.
Quiet engine intake and exhaust characteristics: Care is exercised to engineer out any annoying engine air-intake noise. Standard Critical grade muffler typically reduces tailpipe sound emissions to below 80 dBA (at 1 meter) at full load.
Tuned rubber mounts between the power unit and main frame substantially reduce the transmission of noise and vibration. Transmitting of Secondary vibration to railcar frame is virtually eliminated.
SOUND LEVELS: Results of testing available on request.
Easy to keep clean by design. Exceptionally clean design with an absolute minimum of joints and connections to minimize oil leaks. Lube oil drains directly down through an access plate in the belly pan via self-locking oil drain valve.
Coolant recovery system with see-through reservoir for easy visual monitoring of coolant level and convenient replenishment of coolant.
Optional available Roll Out service track system provides unrestricted access for major service.
Comprehensively written 125 page Operators Instruction Manual and trouble shooting charts make self servicing as easy as possible. Includes unit installation instructions and diagrams.
100 hours (average min.) running time for FULL or ADD level on lube oil dipstick (after engine break-in period).
Cooling air intake area on Service side (outside) to simplify installation on Skirting equipped cars. Reduces heat recirculation potential on all types of cars. See Sales drawings for further installation information.
Optionally available Roll Out service track system provides convenient access to entire unit for major service procedures. In transport position unit rests on (4) bolted rigid mounts. In service position unit rolls out on 48 inch long track extensions. Storage required for track extensions and ground support jacks. ROLL-OUT service track attaches to predrilled holes in generator unit frame using hardware included with track assembly. Installation drawing and instructions included.
A tucked-in configuration belly pan provides additional installation clearance in a critical area.
All electrical connections are wired to terminal strips in dedicated terminal boxes for both AC and DC circuits. Likewise, Remote control panels are equipped with terminal strips to receive conductors from main unit.
Fuel connections (2) are located on outside rear side of the unit.
STADCO supplied exhaust system quickly and easily disconnected by a stainless steel connector.
Current distribution box, located on back side of unit provides for a choice of outlet cable and control cable connections. Cable entry is from the sides of the box. (Distribution box can be relocated to end panel if required for clearance).
All-steel battery compartment designed to mount directly to unit frame. All necessary mounting hardware and battery cables included. Design also permits remote location of battery.
Predelivery Quality Control: Check engine fuel delivery timing and adjust valve clearance, check entire unit against Bill of Materials and against Quality Control check list.
Publications: Electrical diagrams for AC and DC circuit, 125 page operators manual with trouble shooting charts. Complete parts manual containing engine parts numbers in addition to those for all other components.
Heavy timber shipping skid for motor freight shipment to prevent shipment damage.
Specifications and features subject to change without notice. For construction we reserve the right to substitute components or equipment which do not substantially alter Gen-set specifications and overall performance, without notice to customers.