ZF Services UK worked with Rolls Royce MTU and Irish Rail (Iarnród Éireann) to repower Class 22000 Hyundai Rotem Diesel Multiple Units (DMUs), with new EcoWorld transmissions from ZF to enable more efficient operation, improved acceleration and reduced noise.
The existing hydrodynamic transmission was upgraded to a six-speed powershift transmission ZF EcoWorld, featuring an integrated reversing and coasting capability.
The intercity DMUs circulate on the entire IE (Irish) network including the Dublin to Cork line and following the transmission replacement, is set to boast savings of 15 percent in both fuel and CO2, following trial validation.
The project calculated annual savings across the entire Iarnród Éireann InterCity Fleet (ICR) fleet of approximately €2 million, as well as fuel savings of 3,510,000 litres and 35,693,190 per kWh, not to mention CO2 emissions savings of 9,419 tonnes, following fleet fitment.
The units entered passenger service in September 2020 and the energy efficiency improvement has been validated against performance claims.
In total, it was projected that the ZF EcoWorld will provide a 20.7 percent improvement on Heuston Portlaoise Commuter (frequent stops) and an 11.5 percent improvement on Heuston Cork Express routes, according to the trial data.
With mounting pressure on the transport industry to move towards a greener future, which has been further heightened with the launch of the Transport Decarbonisation Plan in July 2021, ZF is actively investing in its repowering technology in support of rail operators.
Simon Hargreaves, business manager rail at ZF Services UK, said: “With less than half of the British rail network currently electrified, these innovative solutions are critical to supporting emissions reductions. We recognise that if rail operators running local and regional services want to remain on track to success, their fleets need to run economically over as long a period as possible.
“For example, in the case of diesel multiple units, fuel costs alone account for more than two thirds of the total life cycle costs of the fleet. By using our state-of-the-art technology, we can actively help to futureproof the rail industry and meet the demands brought about by the recent legislative changes.”
ZF’s UK Centre of Competence in Nottingham provides overhaul, repair and preventive maintenance for ZF and third-party driveline and bogie systems for the rail industry.
In addition to being a leading provider of final drive and transmission overhaul, ZF Services UK has diversified to offer overhaul services for bogies and wheelsets. All these services are within the scope of ZF’s RISAS (Rail Industry Suppliers Approval Scheme) accreditation.
For more information on ZF Service UK’s repowering capabilities, watch this video.
