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Cowl unit

A cowl unit is a diesel-electric body style characterized by a full-width, non-load-bearing carbody that encloses the engine, electrical systems, and other components, providing protection while relying on a heavier underframe for structural support and weight distribution. This design differentiated cowl units from earlier cab units, such as the F-series built from the late 1930s to the 1950s, where the carbody itself contributed to the locomotive's structural integrity. The first production cowl units were 's FP45 and F45 models introduced in 1967–1968. Introduced in the late by major manufacturers including Electro-Motive Diesel () and General Electric (GE), cowl units represented an evolution in locomotive architecture, prioritizing easier maintenance access and a streamlined appearance without compromising the frame's load-bearing role. Cowl units gained prominence in North railroading, with both freight-oriented cowl unit models (like EMD's SD40-2F, SD50F, and SD60F) and variants featuring wide-nose cabs for improved crew visibility and protection. They were especially valued on Canadian railroads, such as Canadian National () and Canadian Pacific (CP), for their enclosed that buffered against extreme cold, with GE's C40-8M (built 1990–1994) marking the last major production run of 84 units tailored for such conditions. However, by the , many cowl units began facing retirement due to challenges like hot operating cabs and reduced visibility compared to modern wide-cab hood units, with ongoing retirements continuing into the ; for example, placed 19 of its 55 C40-8M locomotives up for sale in 2020, and service in certain roles ended by 2024.

Overview

Definition

A cowl unit is a body style of featuring full-width, enclosing bodywork referred to as a "," which serves as a non-load-bearing mounted on a separate underframe or that provides the primary structural strength. This design contrasts with locomotives that incorporate load-bearing bodywork integral to the overall frame. The term "cowl unit" originated as a primarily North American designation in the late 1960s to describe this configuration, though similar full-width, non-structural body styles exist in other regions under different nomenclature. Structurally, the cowl spans the locomotive's entire width, creating a streamlined exterior while encasing internal components such as the diesel engine, generators, and other power plant elements within the non-structural enclosure. This approach differentiates cowl units from hood units, which employ narrower, load-bearing hoods as part of the topside structure, and from earlier cab units like the F-series, where the full-width body forms an integral, structural component rather than a detachable cover.

Key characteristics

The cowl unit features a full-width enclosing bodywork that aligns visually with passenger car profiles, creating a unified and streamlined appearance for mixed consists. This design often incorporates matching liveries across the trainset, such as the Atchison, Topeka and Railway's iconic red-and-silver "warbonnet" scheme applied to its FP45 locomotives. Operationally, cowl units emphasize accessibility and crew protection through removable non-structural panels on the body shell, allowing straightforward maintenance without compromising the underlying frame. Unlike traditional hood units, they lack external walkways or decking, instead providing an internal walk-through that enables en-route inspections and repairs in adverse weather conditions, enhancing safety for personnel. Mechanically, these locomotives integrate power systems onto standard chassis, such as the Electro-Motive Division () SD-series underframe, with the cowl serving as an added shell rather than a load-bearing component. Horsepower ratings typically range from 3,000 to 4,000 hp, mirroring those of their counterparts due to shared diesel-electric propulsion. The design evolved in the as a cost-efficient of open units, where enclosing cowls were fitted to existing to avoid the expense of redesigning the underframe while achieving a more enclosed profile.

History

British prototypes

The London, Midland and Scottish Railway (LMS) constructed the prototypes numbered 10000 and 10001 at its Works as mixed-traffic diesel-electric locomotives, with 10000 emerging in December 1947 and 10001 completing trials in April 1948. These were the first mainline diesel locomotives built in , designed under the direction of Chief Mechanical Engineer H. G. Ivatt in collaboration with English Electric, who provided the engines, generators, and traction motors. Post-nationalization in 1948, they were classified by British Railways as Class D16/1. Each featured a 1,600 hp (1,193 kW) net output English Electric 16SVT sixteen-cylinder driving a generator to power six traction motors on a Co-Co arrangement, enabling a top speed of 93 (150 /h) and a maximum of 41,400 lbf (184 kN). The body adopted an innovative full-width enclosing structure divided into three sections—cabs at both ends with triple windscreens and a central compartment—built from heavy-gauge 'I'-section girders, sheet decking, and internal insulation for weather protection and component access. This cowl-style , where the non-load-bearing body provided aerodynamic streamlining and facilitated , represented Europe's earliest implementation of such a configuration on a mainline . The were intended for paired operation on principal expresses and single use on freight, incorporating Clarkson generators for train heating. Following modifications in late to address early service experience, such as improved cooling and control systems, the pair entered regular service in 1949, allocated to Friary depot on the London Midland Region. They hauled key expresses including the London to and later the Southern Region's Royal Wessex, alongside freight duties, demonstrating reliable performance over nearly two decades despite the experimental nature. No. 10000 was withdrawn in December 1963, followed by No. 10001 in June 1966, as part of British Railways' fleet modernization favoring newer Type 4 designs; both were scrapped in 1968 at Cashmore's, Great Bridge, and Cox & Danks, , respectively, before the diesel preservation era began. Although not mass-produced, the LMS Twins served as conceptual precursors to subsequent British mainline diesels, including the influential English Electric Type 4 (Class 40), by validating the practicality of high-power diesel-electric traction and the enclosing body for operational efficiency in Britain's . A faithful recreation of No. 10000 is under by the Ivatt Diesel Re-creation Society using an original 16SVT engine and a modified Class 58 underframe, aimed at heritage operations.

North American adoption

The adoption of cowl units in began with the introduction of the (, the first commercial model of its kind, ordered by the Atchison, Topeka and Railway and delivered starting in December 1967 for use on flagship passenger trains such as the and . This marked a shift from earlier cab units, as railroads sought modern diesel power that could integrate seamlessly with streamlined passenger consists while addressing the transition away from steam locomotives and aging early diesels. Production of cowl units surged during two key periods: 1968–1974, encompassing models like the (86 units built for freight service on roads including and the future Burlington Northern) and the EMD SDP40F (150 units produced 1973–1975), and 1981–1994, which included extended runs of passenger-oriented variants such as the (over 325 units built, primarily for and commuter operators). Market drivers for this expansion were rooted in the needs of passenger railroads to maintain visual and operational harmony between locomotives and cars, particularly as intercity services faced competition and regulatory changes. The formation of in , which centralized U.S. passenger rail operations and inherited a patchwork fleet, accelerated demand for purpose-built power; the SDP40F, Amtrak's first entirely new acquisition, exemplified this push to modernize long-distance routes with reliable, aesthetically cohesive units. By the late 1970s, growth further boosted orders, with the F40PH becoming a staple for services like those of and . Electro-Motive Diesel initially dominated production, delivering the majority of early cowl units including the FP45, F45, SDP40F, and F40PH series, which accounted for hundreds of examples tailored to both and freight applications. entered the market with the P30CH (25 units built 1975–1976 for ) and later the C40-8M (84 units produced 1990–1994: 55 for Canadian National, 26 for , and 3 for Quebec and Railway), while contributed the HR-616 (20 units for Canadian National in 1982), introducing distinctive features like the Draper Taper for enhanced crew visibility. Overall production exceeded 1,000 units across variants by the mid-1990s, reflecting widespread Class I railroad uptake for services blending aesthetics with diesel efficiency. Adoption waned from the onward as railroads prioritized multi-engine hood units for improved , maintenance access, and emissions compliance in an era of freight dominance and electrified passenger corridors. By the , retirements accelerated, including Canadian National's of 19 C40-8M units in 2020; as of 2025, a few ex-BC Rail C40-8Ms remain in service on , though most have been retired, signaling the end of significant cowl unit fleets on major carriers with few new builds after 1994.

Design features

Advantages

The non-structural design of cowl units facilitates by allowing the entire bodywork to be fully removed from the underframe for major repairs, providing unobstructed access to internal components without the need to disassemble the . This feature streamlines heavy overhauls and inspections, reducing compared to body designs. Additionally, internal walkways within the enclosed structure enable crew members to move between and without external exposure, enhancing accessibility during routine checks or adjustments. The cowl unit's full-width bodywork integrates seamlessly with passenger car consists, creating a train appearance that enhances and operational cohesion. This contributes to reduced aerodynamic at typical passenger speeds, improving over hood units with similar power ratings. Furthermore, the smooth, enclosed exterior allows cowl units to pass through standard passenger facilities more effectively than hood units, whose protruding walkways and inset sides complicate and can . Safety benefits arise from the enclosed body, which deters trespassers and by eliminating external walkways and access points common to hood units, thereby reducing unauthorized entry risks. The fully covered design also provides superior protection for vital components against weather elements like rain, snow, and debris, minimizing corrosion and extending equipment longevity. Crew comfort is notably improved in adverse conditions, as the enclosed interior shields personnel from cold, wind, and precipitation during on-board tasks. Cowl units leverage proven freight , such as those from established platforms, which lowers development and production costs by avoiding the need for entirely new . This approach enables manufacturers to adapt reliable mechanical foundations for service with minimal redesign. For instance, the , a prominent cowl unit model, has demonstrated exceptional , with many units achieving over 40 years of service on railroads like through routine maintenance and targeted upgrades.

Disadvantages and modifications

One significant limitation of cowl units is their poor rearward sightlines, resulting from the full-width enclosing bodywork that obstructs the engineer's view to the rear, thereby elevating collision risks during reverse movements or switching operations. This is exacerbated in bi-directional operations, where modern designs prioritize forward visibility, often necessitating engineers to lean out of side windows or rely on supplementary aids like mirrors for adequate rear observation. To address rear visibility concerns without fully compromising the aesthetic and protective benefits of the design, the Draper Taper modification was introduced in the . Named after Canadian National's chief motive power officer William L. Draper, this adaptation featured a tapered rear section of the , angling inward more than 10 feet behind the cab on locomotives such as the SD50F (built 1985–1987 for ), allowing crews better aft sightlines while preserving engine compartment access. Similarly applied to models like the GE C40-8M and Bombardier HR616, the Draper Taper represented a targeted engineering solution to balance safety and the enclosed carbody style, though early implementations like the HR616 still encountered mechanical reliability challenges leading to early retirements. Additional drawbacks include elevated initial construction costs attributable to the extensive bodywork needed for the full enclosure, as well as restricted access to roof-mounted components such as cooling systems, which complicates compared to open hood units. Enclosed spaces in units can also promote if moisture accumulates, requiring vigilant inspections and protective treatments. Post-1980 engineering adaptations further mitigated visibility limitations through features like expanded areas and more forward positioning to optimize forward and lateral fields of , aligning with ergonomic guidelines recommending at least 180° lateral and clear sightlines to track-level objects 50 feet ahead. For example, the GE P40DC passenger incorporated a rear hostler's window and stand, enabling operation from the opposite end with enhanced reversing capabilities, while its slanted nose design improved both aerodynamic efficiency and overall sightlines. These updates reflect broader efforts to adapt configurations for safer, more versatile operation in diverse rail environments.

Types

Passenger-oriented cowl units

Passenger-oriented cowl units are diesel-electric designed primarily for hauling passenger trains, featuring streamlined that covers the underframe for improved and in commuter and services. These units prioritize reliability, crew comfort, and integration with passenger car systems over high-speed performance, making them suitable for push-pull operations where the locomotive can operate in either direction without turning. The stands as the most prominent example, a 3,000 horsepower (2,200 kW) built between 1975 and 1988, with over 400 units produced mainly for and in . Equipped with a 16-cylinder 645F3B , the F40PH was engineered for dependable service on routes like the , where it powered trains at speeds up to 110 mph (177 km/h). Another early model, the SDP40F, delivered 3,000 horsepower (2,200 kW) and was constructed from 1973 to 1974 exclusively for , with 150 units built on an SDP40 chassis adapted for passenger use; these were tested on the same corridor but faced truck-related issues at high speeds, leading to their withdrawal by the late . In service history, these cowl units were integral to push-pull operations across the and , allowing cab cars at the opposite end of the train to control the remotely, enhancing efficiency on electrified and non-electrified lines. Amtrak's F40PH fleet, numbering 216 units, dominated passenger hauling through the and 1990s on routes including the and , though most were retired by the early 2000s in favor of newer s; several have been preserved in museums or repurposed for excursion service. The SDP40F's brief tenure highlighted early challenges in cowl unit stability, but it paved the way for refinements in subsequent designs. Design adaptations for passenger service include head-end power (HEP) generators, typically rated at 500 kW, which supply electricity for lighting, , and other amenities in trailing passenger cars, eliminating the need for separate generator cars. Full-width cabs provide enhanced crew comfort with improved visibility and space compared to freight-oriented hood units, while the overall of passenger cowl units like the F40PH totaled approximately 500 across variants, emphasizing for frequent starts and stops rather than sustained high speeds. These features contributed to a sleek appearance that aligned with the aesthetic advantages of designs for passenger trains. The operational legacy of passenger-oriented cowl units is profound, as they dominated North American passenger railroading from the 1970s to the 1990s, with the F40PH becoming synonymous with Amtrak's identity and influencing rebuild programs by Industries (MPI), which upgraded dozens of units with modern electronics and emissions controls; as of 2025, over 50 MPI-rebuilt F40PHs remain in active service for commuter railroads like Metrolink and . This enduring influence underscores their role in bridging mid-20th-century diesel technology with contemporary passenger demands.

Freight-oriented cowl units

Freight-oriented units were designed primarily for heavy-haul freight service, featuring robust construction to handle substantial loads while retaining the streamlined, full-width bodywork originally developed for passenger locomotives. These units combined the aesthetic and protective qualities of designs with enhanced structural reinforcements suitable for freight operations, such as thicker frames capable of supporting loads exceeding 100 tons per unit. Multi-unit lashups were standard, allowing several locomotives to operate in tandem for powering long, heavy trains across demanding terrains. The enclosure also offered superior weather protection for crews on extended hauls, reducing exposure to harsh conditions compared to traditional hood units. A prominent example is the Electro-Motive Division (EMD) F45, a 3,600 horsepower six-axle diesel-electric locomotive produced from 1968 to 1970. Built specifically for freight, the F45 featured an EMD 20-645E3 prime mover and was acquired by the Atchison, Topeka and Santa Fe Railway (40 units, numbered 1900-1939) and, through mergers, the Burlington Northern (46 units originally from Great Northern and Northern Pacific), totaling 86 units. These locomotives served in mixed freight and occasional passenger duties on lines like the Santa Fe's transcontinental routes, hauling bulk commodities such as grain and coal through varied landscapes including deserts and mountains. Many F45s remained in service into the 2000s, with some rebuilt to extend their operational life. In , (GMD) produced cowl units tailored for northern freight operations, including the SD40-2F for (CP) Railway, a 3,000 horsepower model built from 1988 to 1989 with 25 units (numbered 9000-9024). Although similar designs were explored for (CN), CP's SD40-2F exemplified adaptations for prairie and mountain runs, where the cowl improved crew comfort in extreme weather. For CN, the GMD SD50F (60 units, 3,600 horsepower, built 1984-1985) and SD60F (64 units, 3,800 horsepower, built 1990-1991) filled similar roles, focusing on heavy freight across the prairies and Rockies. The C40-8M, a 4,000 horsepower 8-series cowl unit built from 1990 to 1994, had total production of 84 units, with an original order of 55 for CN (numbered 2400-2454); CN's effective fleet grew to 81 units after acquiring 26 from in 2004, emphasizing high-traction performance for unit trains of , , and intermodal cargo. These Canadian units often operated in lashups of three or more for mountain grades. Service histories highlight the versatility of these units, with Santa Fe's F45s contributing to postwar freight booms until retirement in the late 1990s. CN's cowl fleet, including the C40-8M, was concentrated on transcontinental lines through the prairies and Canadian Shield mountains, supporting bulk commodity transport. Retirements accelerated in the 2010s due to emissions regulations and fleet modernization; CN began retiring its C40-8M units in the 2010s, auctioning 19 in 2020, with one remaining active in yard service as of September 2024 and full retirement likely by 2025. Overall production of major North American freight cowl units from the 1960s to 1990s exceeded 200 examples across models, though exact totals vary by inclusion of rebuilds. Many surviving units, such as select F45s and SD50Fs, were rebuilt to standard hood configurations like the SD40-2 for continued freight use, underscoring their role as a transitional design blending passenger-era styling with freight reliability during the late 20th century.

Export and license-built cowl units

The export and license-built cowl units adapted the North American design for international freight applications, incorporating modifications for local gauges, climates, and operational demands. A key model is the EMD GT42CU, rated at approximately 3,000 horsepower from its 12-cylinder 710-series engine, which was produced in the 1990s and early 2000s under license by and its successor Downer EDI Rail in Australia. These locomotives were built primarily for railroads such as and , with total production reaching 193 units (GT42CU AC: 61 units built 1999–2005; GT42CU ACe: 132 units built 2007–2013) for 1,067 mm (3 ft 6 in) narrow-gauge operations across various Australian operators. In service, these units have been employed mainly for heavy freight on Australia's narrow-gauge networks, including and intermodal trains, where their full-width body provided improved and crew protection compared to traditional hood designs. Overall production of export units exceeded 200 units globally across models, primarily the Australian GT42CU series, facilitated by license agreements with firms such as for assembly and customization in target markets; post-LMS era developments saw no significant exports. As of 2025, GT42CU units continue to operate reliably in for freight duties, contributing to the evolution of hybrid locomotive concepts through their modular architecture, though international adoption has shifted toward conventional units for cost and maintenance advantages.

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