Keep the journey going…

Keep the journey going…

How OEM overhaul solutions renew the performance and lifespan of mtu PowerPacks.

How overhaul solutions breathe new life into mtu PowerPacks

Rail vehicles run day after day, demanding engines that remain reliable under all conditions. Every mtu PowerPack is built for endurance in daily rail operations. As the Original Equipment Manufacturer (OEM), we restore Series 1600 PowerPacks to factory specification through certified engine remanufacturing and OEM overhaul solutions. Using genuine spare parts, controlled remanufacturing processes, and full-load test-bench validation, each PowerPack is prepared for reliable service and extended lifecycle performance.

With our OEM renewal expertise, you achieve like-new PowerPack performance, reduced downtime, predictable lifecycle costs, and long-term fleet stability — keeping your rail operations moving mile after mile.

… and going with a deeper look into the journey

Original by Design. Watch the PowerPack transform from assembled to disassembled, revealing the critical components that define reliability and lifecycle value. As the structure opens, the base frame and mounted components show which parts are renewed, verified, or replaced during an OEM overhaul — making visible what keeps performance on track.

See what keeps the journey going

… and going with precise component insight

Exceptional in Overhaul.

Explore the mtu PowerPack Series 1600 through interactive hotspots that provide clear, component-level insight. Each highlighted element explains how OEM renewal — from turbochargers and injection systems to cooling elements and electronic control units — contributes to durability, extended service life, and reduced downtime.

Dive into what keeps the journey going

Injection System

High-pressure pump and injectors are renewed to restore precise fuel metering. Fuel lines are cleaned and verified under strict purity standards. Sensors are tested before reuse to support reliable performance throughout extended service intervals.

Cylinder Head

Combustion residues are removed through comprehensive cleaning and inspection. Valve seats and guides are renewed and precision-machined. Seals, valves and springs are replaced to maintain stable combustion across long-term service.

Crankcase

All oil passages are fully cleaned and inspected. Bores are measured to verify alignment and tolerance compliance. Minor surface damage is restored to preserve structural integrity during long-term operation.

Crankshaft

Load-bearing components are assessed according to strict reuse standards. Critical areas undergo crack inspection and surface verification. Connecting rods receive new bushings to ensure durable power transmission under continuous load.

Cooling System

Radiators and charge air coolers are cleaned and leak-tested. Frames are inspected and repaired where required. Fan drive components are overhauled to maintain thermal stability during sustained operation.

Urea SCR System

The catalytic unit undergoes detailed refurbishment and inspection. The catalytic layer is renewed to restore effective NOx reduction performance. Dosing unit and sensors are replaced to maintain emission compliance over time.

Base Frame

Structural surfaces are inspected for damage and deformation. Repairs are carried out by certified welding specialists where required. Bearing journals undergo crack inspection to ensure stable alignment during long-term operation.

Injection System

Cylinder Head

Crankcase

Crankshaft

Cooling System

Urea SCR System

Base Frame

One Journey - Four Perspectives

Every mtu PowerPack follows its own journey — and each role in your organisation contributes to keeping it moving. From operational uptime to technical assurance, fleet planning, and asset value, our OEM overhaul solutions support the needs of all stakeholders involved in the lifecycle of your rail engines.

For Operators

… and going with maximum availability

Daily operations rely on engines that perform reliably — every hour, every day. Our OEM overhauls restore PowerPacks to like-new condition, minimise unplanned downtime, and deliver the dependability your passengers trust.

• OEM warranty comparable to new engines
• Predictable, fast turnaround times
• Proven reliability for daily service

For Technical & Maintenance Managers

… and going with precise OEM insight

Your work keeps the technical heart of every PowerPack beating. That’s why we provide certified documentation (EMU + 3.1), OEM diagnostics, and genuine parts — giving you traceability and confidence for every maintenance decision along your PowerPack’s journey.

• Certification as maintenance provider ECM IV
• Condition-based overhaul strategies
• Genuine parts and OEM testing data

For Fleet Managers

… and going with stable lifecycle costs

Long-term fleet planning requires predictable cost structures and reliable engine performance. Our overhaul reduce lifecycle costs by up to 8–10% and help maintain availability levels of up to 99% — enabling predictable, long-term fleet planning.

• Lower total cost of ownership
• Longer intervals between major services
• Predictable multi-year fleet planning

For Leasing Companies

… and going with protected asset value

Your assets must remain compliant, reliable, and transferable throughout multiple leasing cycles. OEM-certified overhauls protect residual value, reduce operational risks, provide clear documentation, remain compliant and transferable across leasing cycles.

• OEM warranties
• Higher uptime, lower risk

Milestones that prove OEM overhaul value

These figures represent more than performance — they serve as a proof of concept for the value of OEM overhaul, marking the technical milestones of a PowerPack’s lifecycle journey.

24 months

full OEM warranty

Same warranty coverage as for new units — for maximum confidence in every remanufactured unit.

ECM 4

certified maintenance standards

Entity in Charge of Maintenance (ECM) Function 4, delivered from our overhaul facility in Magdeburg.

Up to 99 %

operational certainty

Short turnaround times and reliable slot planning — even for large fleets and complex project setups.

Power that lasts

OEM overhaul and PowerPack remanufacturing solutions that keep your journey going.

Hear from our experts

Our mtu specialists are the people who help keep every journey going. They ensure that each overhauled PowerPack returns stronger, more reliable, and ready for the next chapter of its lifecycle. Here, our experts explain what truly matters for long-term availability, technical clarity, lifecycle planning, and asset value — and how OEM overhauls keep your fleet moving mile after mile.

Proven PowerPacks. Next generation — ready for a second life.

Anette Rennhack Senior Manager Service Rail, Rolls-Royce

Explore how OEM expertise keeps operations reliable — day after day.

Fully dismantled, recertified, and tested — to new-product standards.

Marcus Erdmann Senior Manager Manufacturing – Magdeburg, Rolls-Royce

See how certified processes ensure reliability — mile after mile.

Overhauls don’t just restore engines — they upgrade them.

Maria Saarinen Key Account Manager Service Sales Rail, Rolls-Royce

Discover how overhauls upgrade performance — and keep your fleet moving.

Higher reuse, lower CO₂ — and stronger asset value.

Martin Streeck Senior Manager Quality Management – Magdeburg, Rolls-Royce

Learn how extending asset life keeps value — and the journey — going.

FAQ about mtu PowerPack overhauls

Our OEM overhaul and engine remanufacturing solutions are designed to keep your PowerPack’s journey going — reliably, efficiently and with the certainty only an OEM can provide.

Turnaround times are planned to minimise downtime and fit into your operational schedule.

Yes — with OEM tolerances, calibrated systems and warranties comparable to new engines.

It can reduce operating expenses by up to 8–10% and extends service inter