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Diesel multiple unit

A diesel multiple unit (DMU) is a type of consisting of multiple carriages, each equipped with its own and system, allowing the train to operate without a separate . These self-propelled units are designed for efficient operation on non-electrified tracks, typically serving regional, suburban, or services where traffic volumes are moderate. DMUs integrate one or more and a system—such as mechanical, hydraulic, or electric—directly into the passenger cars, enabling flexible formation of two- to four-car sets that can be coupled or uncoupled as needed. The origins of DMUs trace back to the mid-20th century, building on diesel railcars introduced in , emerging as a cost-effective alternative to amid declining passenger ridership on lighter rail routes in the post-World War II era. , the Budd Company's Rail Diesel Car (RDC), introduced in 1949, marked a pivotal development as the first widely adopted DMU, with prototypes unveiled at Chicago's to address operational inefficiencies on low-density lines. Between 1949 and 1962, Budd produced nearly 400 RDCs, which were deployed across North American railroads for short-haul services, offering higher speeds and lower maintenance costs compared to traditional locomotive-hauled trains. , DMUs gained prominence through British Railways' 1955 Modernisation Plan, which aimed to replace steam traction with diesel-powered units for rapid deployment on extensive rural and secondary networks. DMUs have since evolved into a of global rail operations, particularly in regions without widespread , with modern variants incorporating advanced diesel-electric or diesel-hydraulic transmissions for improved and emissions control. They are prevalent in , , and developing rail systems, supporting commuter services like those on the U.S. Railroad Administration-compliant lines or operations in corridors. Key advantages include reduced crew requirements, quicker acceleration for frequent stops, and adaptability to varying route demands, though challenges such as noise, vibration, and environmental impacts have driven ongoing innovations toward and low-emission models.

Definition and history

Definition and characteristics

A multiple unit (DMU) is a self-propelled vehicle powered by one or more onboard engines integrated into the carriages, enabling operation without a separate . These units are designed as standardized trainsets where multiple carriages can be coupled to function as a single train, with power distributed to one or more axles per powered car. DMUs are typically lighter and shorter than traditional locomotive-hauled trains, making them suitable for regional, suburban, or passenger services. Common configurations include 2-car or 3-car sets, often with high- or low-floor designs to accommodate varying heights and accessibility needs. They feature semi-permanently coupled vehicles for flexibility on lower-demand routes, with seating capacities ranging from approximately 90 to 144 passengers per unit depending on the model. Unlike diesel locomotives, which pull unpowered coaches from a dedicated leading or trailing position, DMUs incorporate propulsion engines directly into the powered end cars, allowing for and more efficient short-haul operations. In contrast to electric multiple units (EMUs), which draw power from overhead lines or third rails, DMUs rely solely on onboard , eliminating the need for infrastructure. DMUs support capability, enabling several units to be coupled and controlled from a single for extended formations. Typical top speeds range from 75 to 125 km/h (47 to 78 mph) for regional services, with acceleration and deceleration rates optimized for frequent stops on suburban or branch lines.

Historical development

The origins of diesel multiple units (DMUs) trace back to the early , with initial experiments in self-propelled railcars emerging as economical alternatives to on branch lines and rural routes. In the , the Great Western Railway (GWR) pioneered diesel railcars in , introducing the first unit in 1933 equipped with an diesel engine and mechanical transmission, followed by a series of 38 diesel-powered vehicles built between 1934 and 1942 that demonstrated reliable performance on secondary services. In the United States, early diesel railcars appeared in , such as the 1933 Texas and Pacific Silver Slipper, a gasoline-electric demonstrator that influenced later designs, though widespread adoption was limited until postwar years. The (RDC), introduced in 1949 by , marked a significant milestone as the first standardized diesel multiple unit in , featuring lightweight construction and diesel-mechanical power for efficient operation on low-density passenger routes. Between 1949 and 1962, 398 RDCs were produced, serving railroads across the continent and setting a template for self-propelled passenger vehicles that reduced crew requirements compared to locomotive-hauled trains. Post-World War II dieselization accelerated DMU development, particularly in the 1950s amid global rail network modernizations to replace aging steam fleets. In the UK, British Railways' 1955 Modernisation Plan prioritized DMUs for cost-effective local services, leading to the introduction of production units like the Metro-Cammell Class 101 in 1956, which became one of the most numerous first-generation designs with over 550 vehicles built by 1959. This era saw a boom in Europe and North America, where DMUs addressed labor shortages and fuel efficiency needs during economic recovery. During the and , manufacturers emphasized hydraulic transmissions in DMU designs for smoother power delivery and compact integration, as seen in and models that favored this system for railcars due to its reliability on varied terrains. By the and , a shift toward diesel-electric transmissions gained prominence, offering improved and flexibility for higher-speed operations, particularly in upgraded networks. In , DMU usage declined from the 1970s onward as extensive electrification programs converted main lines to electric multiple units, reducing the need for diesel on high-traffic routes and leading to the phasing out of many first-generation fleets by the 1990s. However, DMUs experienced resurgence after 2000 in developing countries, where non-electrified lines proliferated; for instance, modern units were adopted in regions like the and for rapid infrastructure expansion on secondary networks. Globally, initially spread in and during the mid-20th century before expanding to from the mid-20th century, with early examples such as Japan's KiHa series introduced in the , supporting growing suburban and regional services on unelectrified tracks.

Advantages and disadvantages

Advantages

Diesel multiple units (DMUs) offer significant economic benefits over traditional locomotive-hauled trains, primarily due to their that combines and accommodation in self-propelled vehicles. This eliminates the need for separate locomotives, reducing for acquisition and modifications, while lowering expenses through simpler systems and fewer components requiring upkeep. For instance, combined fuel and costs for DMUs can be approximately 35% lower than for comparable locomotive-hauled consists in regional . Additionally, DMUs typically require reduced staffing, often operating with a single driver, which cuts labor expenses compared to the two-person crews common on locomotive-hauled trains. Faster turnaround times at terminals are achieved by simply switching the driver between cab ends, avoiding the need to reposition locomotives. Operationally, DMUs provide enhanced efficiency, particularly for stop-start services on regional routes. Their systems enable quicker acceleration, with power-to-weight ratios that surpass those of locomotive-hauled trains, allowing for shorter dwell times at stations and improved schedule adherence. capability facilitates the formation of variable-length trains by coupling units electronically, enabling operators to adjust consists dynamically to match without complex shunting. This makes DMUs especially suitable for low-density routes, where full locomotives would be uneconomical due to underutilized and higher fuel demands; for example, fuel consumption for DMUs averages 0.33 gallons per vehicle-mile, compared to 2.23 gallons per train-mile for locomotive-hauled equivalents. The flexibility of DMUs extends to simpler coupling and uncoupling procedures, supporting short turns and efficient reconfiguration at endpoints, which is ideal for branch lines and rural services. Operators can run single units for light loads or combine them seamlessly, enhancing adaptability to fluctuating volumes without dedicated yard facilities. From an environmental and perspective, DMUs generally produce lower emissions per passenger-kilometer than older or locomotive-diesel setups, thanks to improved —approximately 5-10% better energy use per vehicle compared to equivalent locomotive-hauled trains—and the ability to incorporate or advanced engines. Modern variants further enhance this with 20-30% additional savings and reduced emissions. The cab-forward design at both ends enhances driver visibility, reducing collision risks by providing unobstructed forward and rearward views during operations. Overall, these advantages translate to savings of approximately 5-10% in regional service operations relative to locomotive-hauled trains.

Disadvantages

Diesel multiple units (DMUs) generally exhibit lower total power output compared to locomotive-hauled trains, which restricts their operational suitability for steep gradients or high-speed mainlines. Individual DMU engines typically range from 130 to 560 kW, whereas locomotives often exceed 560 kW, resulting in reduced and on demanding terrains. This power disparity often results in DMUs being operated in 2-4 formations for optimal performance on regional routes. The distributed placement of engines across multiple cars in DMUs introduces significant maintenance challenges, increasing overall complexity and repair durations compared to centralized locomotive systems. Servicing requires access to numerous engine compartments, often necessitating specialized facilities that can cost tens of millions to establish or , such as the estimated $54.6 million for a dedicated DMU . Additionally, the design can lead to higher if multiple units require simultaneous servicing. On-board diesel engines contribute to elevated interior and levels, diminishing passenger comfort particularly on extended journeys. measurements on DMUs, such as the Kustpilen Y2 model, reveal indices exceeding 3.0 on suboptimal tracks, leading to difficulties for two-thirds of passengers in sedentary tasks like reading and writing. These effects stem from engine-induced oscillations in the 1-10 Hz range, amplified at seats and tables, which surpass general perception thresholds of 65 VdB and approach annoyance levels of 75 VdB. Retrofitting older DMUs to comply with modern emissions standards presents substantial technical hurdles, including power and structural modifications. For instance, converting engines to compatibility reduces output from 600 kW to 400 kW due to altered ratios and injection systems, with retrofit costs ranging from €8,000 to €12,000 per . In harsh environments, such upgrades exacerbate wear, contributing to shorter operational lifespans as components like high-pressure tanks face accelerated degradation. Increasing regulatory pressure for zero-emission transitions, such as and standards as of 2025, may further limit the viability of pure DMUs. Economically, DMUs incur higher per-unit costs owing to low-volume production runs, which limit in . Industry reports highlight the challenges of high-mix, low-volume rail production, driving up unit prices relative to mass-produced alternatives. Furthermore, their design is less scalable for very high-capacity urban services, often resulting in underutilization on low-ridership routes, while capital investments for fleets and can exceed $300 million.

Design and technology

Core design principles

Diesel multiple units (DMUs) feature a modular structural centered on powered end cars, or power cars, equipped with driver's cabs to facilitate operation from either direction. These end cars house the primary systems, while intermediate cars can be either powered to distribute motive power or configured as unpowered trailers to extend train length without adding engines. This arrangement allows for scalable formations, from single cars to multi-unit consists, optimizing operational flexibility on lines and regional routes. methods emphasize lightness and durability, often utilizing designs where the body shell integrates the underframe, sides, and roof into a single welded structure, or traditional underframe approaches with stressed-skin panels to resist bending forces while reducing overall mass. Engine integration forms a cornerstone of DMU design, with on-board diesel engines—typically rated at 200-600 kW per car—mounted under the floor or at the vehicle ends to preserve interior space for passengers. This underfloor placement positions the engine within the underframe alongside key components like the drive line, minimizing protrusion into the passenger area and enabling a low center of gravity for stability. Fuel tanks are incorporated directly into the chassis for balance and protection, often with capacities supporting 500-1000 km ranges. Cooling systems use radiators and fans integrated into the underbody to dissipate waste heat and maintain optimal engine temperatures during extended runs, while heating systems utilize engine waste heat for passenger comfort. Passenger accommodations in DMUs are tailored to service type, with commuter variants prioritizing high-density seating arrangements—often 2+2 across with minimal aisles—to maximize capacity on routes, accommodating up to 80-100 passengers per . Regional DMUs, by contrast, blend fixed seating with open areas for standing, providing 50-70 seats per to suit mixed loads on longer trips. Since the , has been enhanced through low-floor designs that lower the car floor to near-platform height, incorporating features like wide , deployable ramps, and dedicated spaces to comply with standards such as the Americans with Disabilities Act. Safety and control systems ensure reliable multi-car operation, with (ATC) integrated to monitor speed, signal adherence, and automatic braking in response to trackside signals or obstacles. Multiple unit control (MUC) synchronizes , engine starting, and across cars via electrical and pneumatic jumpers, allowing a single driver to manage the entire consist seamlessly. Braking combines pneumatic systems for immediate, stopping using actuators on each , supplemented by that converts back to electrical power for dissipation or regeneration, reducing mechanical wear and heat buildup. Materials selection focuses on lightweight alloys to balance strength and , employing high-tensile steel for underframes and aluminum panels for bodywork to curb tare weights to 35-50 s per car. This approach yields power-to-weight ratios of 5-10 kW/, enabling responsive up to 0.5 m/s² on gradients and curves without excessive fuel use.

Transmission types overview

The in a diesel multiple unit (DMU) serves to convert the rotational generated by the onboard into traction force at the wheels, enabling efficient while managing key factors such as , torque multiplication for , and operational control complexity. This conversion is essential for adapting the engine's output to varying load and speed demands in passenger service, where smooth starts, stops, and cruising are prioritized over heavy freight hauling. DMU transmissions are classified primarily by their method of energy transfer from the to the wheels: diesel-mechanical, which uses direct gearing; diesel-hydraulic, employing fluid torque converters; or diesel-electric, involving electrical generation and motor drive. The selection of a transmission type depends on route characteristics like and frequency of stops, as well as economic considerations including initial cost and long-term maintenance requirements. In general, transmissions suit simpler, low-power DMUs due to their straightforward and minimal components, offering ease of in compact underfloor layouts. Hydraulic systems provide smoother power delivery and better low-speed for medium-distance routes with frequent , while electric transmissions excel in versatility for higher-performance applications, allowing precise and multi-unit . These differences influence overall , with types emphasizing simplicity and hydraulics and electrics favoring adaptability. Historically, early DMUs in the mid- predominantly featured mechanical transmissions for their reliability in basic designs, evolving toward hydraulic systems in the for improved torque handling, particularly in railcars. By the late , electric transmissions gained prominence in modern DMUs for enhanced reliability and efficiency, reflecting a broader trend toward electrical systems in self-propelled vehicles. Transmission efficiency typically ranges from 70% to 90% across types, with systems achieving the highest due to direct transfer and minimal losses, while hydraulic and electric incur greater slippage or conversion inefficiencies. This impacts , where DMUs commonly achieve 0.5 to 1 m/s² under typical operating conditions, varying by output and response.

Diesel-mechanical transmission

A diesel-mechanical transmission in a diesel multiple unit (DMU) directly links the to the wheels via a , gearbox, and final drive system, typically using cardan shafts to transmit power to the bogie axles. This setup often employs an epicyclic gearbox with multiple gear ratios—such as four-speed configurations—for efficient power delivery across varying speeds, sometimes incorporating a fluid flywheel as an automatic and a to prevent reverse rotation. The design ensures straightforward mechanical power transfer without intermediate fluid or electrical conversion. The primary advantages of diesel-mechanical transmissions lie in their and low weight, which reduce overall mass and costs, making them particularly cost-effective for short-route and operations. They achieve high , often around 95% in , surpassing the approximately 85% typical of hydraulic or electric alternatives due to minimal losses in direct modes. This supports optimized engine loading, especially with multi-speed setups like 16 ratios in advanced designs. Diesel-mechanical transmissions have been applied in early lightweight DMUs and continue in some modern regional railcars suited to rural or branch line services. Notable examples include the United Kingdom's "Bubble Cars" from the 1960s, which used a single-car configuration with two 150 hp engines and an R14 epicyclic gearbox for flexible, low-capacity operations. More contemporary implementations appear in units like the Danish State Railways' , a three-car articulated DMU with mechanical transmissions providing strong acceleration for intercity and regional routes. Key limitations include interruptions in power delivery during gear shifts, which can affect smooth acceleration compared to fluid-based systems. These transmissions are generally unsuitable for high-power outputs exceeding 300 kW, as the direct mechanical linkage subjects gears and shafts to excessive stress under heavy loads. Additionally, they offer limited capabilities, relying more on traditional brakes. Maintenance for diesel-mechanical systems benefits from fewer complex components than hydraulic or electric variants, lowering long-term costs in simple setups. However, in multi-car formations, precise of multiple engines and gearboxes is essential to ensure even distribution and prevent drivetrain vibrations or uneven wear.

Diesel-hydraulic transmission

In diesel-hydraulic transmissions for diesel multiple units (DMUs), from the is transferred to the wheels via a hydraulic that utilizes and to drive a gearbox, enabling smooth and efficient without direct linkage. The core mechanism involves a or , rotated by the engine, which circulates (typically oil) to impart to a connected to the input shaft of the gearbox; as the turbine accelerates, fluid impingement decreases, allowing variable multiplication during startup and low speeds. Prominent systems include those developed by , which integrate hydrodynamic with multi-stage designs for optimized delivery in rail applications. Key features of these transmissions include seamless acceleration without gear clashes, as the fluid coupling allows slip between engine and transmission components, providing progressive buildup ideal for urban routes with frequent stops and starts. They offer hydrodynamic efficiency curves that peak at 75-85% under optimal operating conditions, balancing power transfer with minimal energy loss through , though efficiency drops at extreme speeds or loads. This design excels in mid-range delivery, making it suitable for lighter railcars on secondary lines. Diesel-hydraulic transmissions gained prominence in during the 1950s to 1980s, particularly in , where they powered efficient DMUs for regional services on lighter infrastructure. A representative example is the German Federal Railway's VT 08 series, introduced in the early 1950s, which used engines paired with hydraulic transmissions for reliable operation at speeds up to 140 km/h on non-electrified lines. While less common in the UK, similar systems influenced designs like certain DMUs, though adoption favored variants; their use persists in exported models to , such as Voith-equipped units in Southeast Asian networks for cost-effective rural connectivity. Despite these strengths, limitations include potential fluid leaks from seals under vibration and pressure, which can reduce lubrication and lead to component wear, as well as heat buildup in the torque converter during prolonged operation, necessitating robust cooling systems. These transmissions are generally heavier than mechanical alternatives due to the added fluid reservoirs and housings, contributing to higher axle loads on tracks. Their decline in modern applications stems from stricter emissions regulations favoring electrified or hybrid systems, though retrofits remain viable for legacy fleets. Engineering specifics involve multi-stage torque converters, where multiple impeller-turbine sets provide variable gear ratios—typically 4:1 to 6:1 in the first stage—allowing adaptation to engine speed without manual shifting, often integrated with automatic planetary gearboxes for seamless progression through four to six speeds. Voith's DIWA and RailPack systems exemplify this, combining hydrodynamic elements with electronic controls for precise ratio adjustments in DMUs.

Diesel-electric transmission

In diesel-electric transmission systems for diesel multiple units (DMUs), the drives a or to produce electrical power, which is then supplied to traction motors mounted on the axles to propel the train. This setup allows for distributed power across multiple cars without requiring a separate . Variants include - systems, where a powers traction motors via resistance control; - systems, where an 's output is rectified to for motors; and modern -- systems, where output is rectified to and then inverted to three-phase for traction motors, offering superior performance in contemporary designs. Key features of diesel-electric include precise speed and torque control through electronic systems, enabling smooth acceleration and adherence to varying track conditions. These systems achieve high efficiency, typically 85-90%, due to the direct and minimal losses compared to other types, while modern units incorporate , where traction motors act as generators during deceleration to recover energy and reduce wear on friction . This capability enhances overall energy utilization, particularly in stop-start suburban operations. Diesel-electric transmissions have become dominant in DMUs introduced after the , providing flexibility for services on non-electrified lines, including those shared with freight traffic due to their compatibility with standard rail infrastructure and ability to handle varied loads. Representative examples include the UK's Bombardier Voyager, a four-car high-speed unit introduced in 2001 for intercity routes, and India's Diesel Electric Multiple Unit (DEMU) series, such as the 1400 HP models used for suburban and regional passenger services since the early 2000s. Despite these advantages, diesel-electric systems incur higher initial costs and greater complexity from the electrical components, leading to elevated manufacturing and installation expenses relative to mechanical alternatives. Electrical faults, such as traction motor flashovers or generator failures, can immobilize entire units, requiring specialized diagnostics and repairs that disrupt service. Advancements in this transmission type include the adoption of (IGBT)-based inverters for drives, which enable finer control, reduced switching losses, and improved reliability in variable-speed operations. By the 2020s, integrations combining diesel-electric systems with onboard batteries have emerged, allowing for and short battery-only runs to cut emissions; examples include the UK's Stadler Class 756 FLIRT DMUs, introduced in 2024 for regional services in .

Global usage

European usage

Diesel multiple units (DMUs) are extensively deployed across , particularly on non-electrified rural and regional lines where they provide efficient, self-propelled passenger services without the need for separate locomotives. In the , the fleet is one of the largest in the region, with approximately 1,500 units (as of 2023) serving local and rural routes, exemplified by the Class 150 Sprinter and Class 156 Super Sprinter, which operate at speeds up to 75 mph (120 km/h) on networks like those managed by . These units have been integral to maintaining connectivity in areas not yet electrified, supporting daily commuter and inter-urban travel. Germany features a robust DMU presence with around 800 units (as of 2023) focused on regional express services, including the Stadler Regio-Shuttle RS1, which runs at 120 km/h on lines such as those in and , emphasizing short-distance, high-frequency operations. In , the SNCB's I11 units, introduced in the 2000s, handle local services on non-electrified branches at speeds around 120 km/h, enhancing accessibility in and . Croatia employs tilting DMUs like the HŽ Series 6112 for intercity routes through hilly terrain, achieving up to 160 km/h to connect with coastal areas. The utilizes the RegioPanter for cross-border regional services, operating at 160 km/h on lines linking to neighboring countries like and , promoting seamless . Estonia has modernized its DR1 series railcars, including the DRZ1 variant, for domestic routes at 120 km/h, addressing the legacy of Soviet-era equipment with upgrades for reliability. Greece maintains limited DMU operations, primarily on island networks like those served by converted units on and , focusing on tourist and local shuttles at lower speeds of 80-100 km/h. In Ireland, the 22K class Civity DMUs from provide intercity services at 160 km/h on routes from to and , replacing older locomotives for improved efficiency. Italy deploys regional ETB (Elettrenord ) units and similar DMUs for suburban and inter-regional lines at 130-160 km/h, such as those operated by in the north. Romania has converted ex-Soviet railcars, like the 92 series, for secondary lines at 100 km/h, adapting them for modern passenger needs amid infrastructure challenges. Slovakia's ZSSK operates classes such as 670 and 672 DMUs for regional services at 120 km/h, connecting to rural areas and supporting cross-border links with and . Recent trends in include the gradual phasing out of older diesel units in favor of low-emission and battery-assisted DMUs by 2025, driven by environmental directives, with examples like the RegioJet's battery-electric-diesel multiple units ordered from Group in 2025 for services in the . The is advancing standardization efforts through initiatives like TSI (Technical Specifications for ) to enhance cross-border DMU operations, targeting interoperability for units operating at 100-160 km/h. Hydraulic transmissions remain a legacy preference in for their torque efficiency in regional starts and stops.

North American usage

In , diesel multiple units (DMUs) have seen limited adoption compared to , largely due to the predominance of freight networks that prioritize heavy-haul operations over passenger services, leading to a focus on commuter, regional, and tourist applications where DMUs provide efficient, self-propelled alternatives to locomotive-hauled trains. Historical use peaked in the mid-20th century with models like the (RDC), but declined through the 1970s amid reduced domestic manufacturing and public investment in ; a modest resurgence began in the late 1990s with demonstrations of European and Asian designs. By the , DMUs represent a small fraction of passenger fleets, emphasizing lightweight yet regulation-compliant vehicles for shorter routes. Regulatory factors significantly constrain DMU deployment, particularly in the United States, where the (FRA) enforces crashworthiness standards under 49 CFR Part 238 to protect occupants in collisions with heavy freight equipment. These require structures capable of withstanding 800,000 pounds of compressive end load, 300,000 pounds at cab corner posts, and anti-climbing mechanisms rated at 100,000 pounds, often necessitating heavier steel construction that increases costs and limits speeds compared to lighter international designs. In and , similar safety rules apply, though with variations; there is increasing advocacy for bi-modal (diesel-electric) DMUs to enable shared use of electrified and non-electrified tracks, enhancing versatility in mixed infrastructure. In the United States, notable implementations include the Sonoma-Marin Area Rail Transit () in , which launched commuter service in 2017 using 14 DMUs configured in two- or three-car sets powered by 760-horsepower Cummins QSK19-R engines compliant with EPA Tier 4 emissions standards. These units accommodate 180 to 237 seated s each, with for bicycles and wheelchairs, and operate at speeds up to 79 mph (127 km/h) along a 71-mile route from to , integrating with heavy-rail corridors while adhering to FRA rules. Demonstrations, such as DMUs tested on routes like the Fullerton-Irvine line in the early , highlighted potential for regional services but faced hurdles in scaling due to regulatory adaptations. Canada's usage centers on remote and regional lines, with operating over 100 self-propelled railcars, including RTC-85SP/D units derived from Budd RDC designs, for passenger and mixed services in since the 1970s. Via Rail Canada continues to deploy Budd RDCs—early DMUs with 270-horsepower engines—as the last mainline examples in on routes like the Sudbury-White River line, valued for their reliability in low-density areas. In Mexico, DMUs support tourist operations, exemplified by the Tren Maya line's four Alstom X'trapolis four-car sets introduced in 2023, each seating 230 passengers and using ultra-low-sulfur diesel for 900 km of scenic Yucatán Peninsula routes at speeds up to 130 km/h. Central American examples include Costa Rica, where the Instituto Costarricense de Ferrocarriles (Incofer) introduced eight CRRC DMUs in 2019 for commuter services around San José, each 38 meters long and carrying up to 372 passengers to replace aging Spanish-built units on urban lines. Post-2010 trends indicate a revival driven by urban rail expansions and emissions regulations, with challenges persisting in integrating DMUs with freight-heavy , including compatibility with Class 1 tracks, signaling for single-unit shunting, and maintenance training, while operational speeds rarely exceed 130 km/h to ensure safety.

Asian and Oceanian usage

In and , diesel multiple units (DMUs) have seen rapid adoption on non-electrified routes, particularly in developing networks where cost-effective, self-propelled trains address diverse and freight needs in rural and regional areas. This proliferation supports economic growth in populous regions, with DMUs offering flexibility for mixed traffic operations amid ongoing efforts. In , Rail's Diesel Tilt Train, introduced in 2003, exemplifies high-speed regional service on the 1,067 mm network, achieving operational speeds up to 160 km/h on the to route while incorporating tilting technology for curved tracks. Railways has incorporated locally assembled and imported DEMUs, such as the 20 units from CNR since 2013, to enhance commuter services on metre-gauge lines. Country-specific deployments highlight tailored applications across the region. In Cambodia, Royal Railway operates Japanese-sourced KiHa 183 series DMUs, acquired in 2024, which serve both passenger and limited freight-hybrid roles on routes like Phnom Penh to Sihanoukville, supporting tourism and logistics in under-electrified areas. China employs regional DMUs like CRRC's double-deck variants for suburban services, complementing its vast high-speed electric network, with over 168 CRH6-series configurations produced by 2023 for commuter operations at speeds up to 200 km/h. India's Indian Railways maintains a massive DEMU fleet exceeding 1,000 units as of 2023, primarily diesel-electric types operating at 100 km/h for short-haul passenger services across non-electrified sections, with multiple units allowing up to four rakes in formation. In Indonesia, Kereta Api Indonesia (KAI) utilizes economy-class KRDI DMUs built by PT INKA, capable of 100 km/h, for intercity and regional routes on Java's network. Japan's JR Group relies on the KiHa series, such as the KiHa 100 and KiHa 110 introduced in 1990, for rural non-electrified lines, emphasizing lightweight construction and diesel-mechanical propulsion for efficient local services. Malaysia's (KTM) deploys Class 61 DMUs since 2015 for operations on non-electrified west coast lines, offering air-conditioned comfort at speeds up to 120 km/h. In the Philippines, (PNR) has tested hybrid diesel-electric units like the 2019 prototype, combining diesel engines with battery storage for 80 km/h operations on lines, aiming to reduce emissions. South Korea's operates legacy DMUs like the 9500 series, though phasing out diesel passenger units by 2029 in favor of electrification. Sri Lanka Railways uses ex-Indian DEMUs from , including six 13-car sets delivered since 2018, for coastal and routes at 100-120 km/h. Taiwan Railways incorporates diesel variants in its DR series, such as the DR3100, for regional services on non-electrified branches. Thailand's State Railway (SRT) employs refurbished KiHa 40 DMUs from on the Red Line and northeastern routes, with 20 units tested in 2025 for feeder services at 100 km/h. Regional trends indicate DMUs are increasingly displaced by in urban corridors, such as Malaysia's expansions and Thailand's Red Line EMU integrations, prioritizing higher capacity and lower emissions. By 2025, hybrid diesel-electric configurations are gaining traction to meet emission standards, with prototypes in the and market forecasts showing hybrid DMU growth at a 5-7% CAGR amid global rail decarbonization. Typical operational speeds range from 80 to 140 km/h to balance efficiency and infrastructure constraints.

Usage in other regions

In , diesel multiple units (DMUs) are employed primarily for commuter and regional services, with a strong emphasis on durability to withstand rough tracks and challenging terrain. Kenya Railways operates a fleet of second-hand DMUs, acquired from , on the Nairobi Commuter Rail network, providing capacity for up to 1,200 s per unit and integrating with the (SGR) for sidings and short-haul operations. In , Madarail maintains a small fleet including one DMU as part of its 11 diesel locomotives and passenger coaches, supporting limited freight-passenger mixed services on aging . 's Passenger Rail Agency of South Africa (PRASA) has pursued limited conversions of existing into DMUs to enable rural rail solutions, addressing underutilized lines with diesel-powered flexibility. In Latin America, DMU deployments focus on regional connectivity, often featuring air-conditioned sets for extended journeys in varied climates. Argentina's Trenes Argentinos operates CNR-built DMUs on the Belgrano Sur line for suburban and regional routes, while a 2019 contract with CRRC delivered 50 additional DMUs to enhance medium-distance services with improved passenger comfort, including climate control for long-haul operations. In Brazil, Vale S.A. utilizes DMUs for tourist excursions on the Estrada de Ferro Vitória a Minas, such as the Ouro Preto–Mariana route, where air-conditioned units facilitate scenic, long-distance travel amid mining corridors. Beyond major continents, DMU adoption remains minimal but includes demonstration projects tailored to specific needs. In the , the ' awarded a contract in 2023 for 21 CRRC-manufactured high-speed DMUs, with deliveries commencing in 2025 and passenger services expected to begin in 2026, marking the nation's first mainline passenger fleet capable of 200 km/h operations across desert terrain, with designs incorporating dust-proofing for arid conditions. In the Pacific islands, ferrobus-style railbuses—compact DMU variants—see rare use on isolated networks, such as short-haul services in and , prioritizing low-maintenance operations over extensive fleets. Regional trends highlight aid-driven imports from and , enabling small-scale modernizations; for instance, most and Latin American operators maintain fleets under 100 units per country, often sourced via development financing to upgrade legacy systems. Adaptations for harsh environments, such as enhanced dust-proofing and robust suspensions, are common to handle sandy or tropical conditions, as seen in UAE and deployments. Challenges include political instability disrupting maintenance schedules and the need to integrate DMUs with colonial-era tracks, which often feature narrow gauges and inconsistent alignments, limiting scalability in countries like and .

Manufacturers and production

Major manufacturers

Alstom, headquartered in , has emerged as a leading producer of diesel multiple units (DMUs) following its 2021 acquisition of . The company's Coradia family, including the LINT and Regional variants, emphasizes modular designs that allow flexible configurations for regional and commuter routes, enabling customization of interior layouts and power systems while maintaining high standards of and passenger comfort. Alstom's focus on integrates and low-emission options into its DMU offerings, supporting transitions toward greener rail operations across . Siemens Mobility, based in , specializes in the Desiro platform, a versatile DMU family deployed widely in for regional services, with models like the Desiro Classic featuring diesel-hydraulic or diesel-electric propulsion for speeds up to 160 km/h. Known for its innovative designs and digital integration, such as systems, has supplied Desiro units to operators in countries including the , , and , enhancing network reliability on non-electrified lines. Spain's () offers the Civity platform, a modular DMU designed for adaptability in length and capacity, serving markets in the UK, , and with features like low-floor access and ergonomic seating. 's emphasis on lightweight materials and advanced contributes to , making Civity units suitable for both urban and rural deployments. Poland's PESA Bydgoszcz SA has gained prominence through its export-oriented production, delivering DMUs like the RegioFox and series to international operators in the , , and , focusing on cost-competitive designs with modern interiors and compliance with European standards. PESA's growth in exports underscores its role in providing affordable, reliable units for emerging rail networks. In , the Budd Company's Rail Diesel Cars (RDCs) represent a historical milestone, with 398 units produced between 1949 and 1962, pioneering self-propelled stainless-steel DMUs that influenced global designs for lightweight, efficient passenger services. For contemporary production, Japan's manufactures FRA-compliant DMUs tailored for U.S. markets, including the two-car sets for California's Sonoma-Marin Area Rail Transit (SMART), emphasizing features and compatibility with American . South Korea's contributes through its DMU exports and domestic models, such as those supplied to the Philippines' , incorporating advanced diesel engines for tropical climates and high reliability. China's Corporation Limited dominates Asian production with its extensive DMU lineup, including diesel-electric models for domestic high-density routes and exports to the UAE, leveraging for cost-effective that has enabled rapid fleet expansions. 's facilities produce thousands of units annually, focusing on standardized components to reduce lifecycle costs while meeting international emission standards. In , the (ICF) under manufactures diesel-electric multiple units (DEMUs) like the 1600 HP AC-AC series, with over 67 trainsets built for non-electrified networks, prioritizing local sourcing and rugged designs for diverse terrains. BEML Limited collaborates with ICF on rail vehicle production, including contributions to high-speed prototypes that incorporate DMU elements, supporting India's push for indigenous manufacturing. Japan's produces KiHa-series DMUs, such as the KiHa 100 and 110, for East and other operators, known for their compact, efficient layouts suited to rural and regional lines with speeds up to 130 km/h. expertise in systems enhances these units' environmental performance, with exports like the RHN series to demonstrating adaptability to international specifications. These manufacturers prioritize export markets, with and leading in global deliveries through customizable platforms that address varying regulatory and operational needs. Europe accounts for approximately 70% of global DMU production, driven by established firms like and , while Asia's share has risen to over 20% by 2025, fueled by 's scale and India's local initiatives. In recent years, the production of multiple units (DMUs) has shifted toward modular techniques, enabling greater and efficiency in manufacturing by allowing components like power packs and interiors to be standardized yet interchangeable across models. This approach has been particularly beneficial in adapting existing DMUs for configurations, reducing time and costs while facilitating retrofits. Global supply chains for DMU components faced significant disruptions in the early 2020s due to geopolitical events and the , prompting a resurgence in local production initiatives, such as India's emphasis on domestic manufacturing under the program to bolster self-reliance in rail vehicle . Key innovations in DMU production include the integration of hybrid diesel-battery (DMU-BEMU) systems, where existing diesel units are converted to operate in zero-emission modes for urban or non-electrified routes. For instance, the UK's HybridFLEX program retrofitted a Class 168 DMU with battery-hybrid power packs, allowing seamless switching between and battery propulsion to eliminate emissions in sensitive areas. Additionally, digital twins—virtual replicas of physical DMUs—have been employed in design and testing phases to simulate performance, optimize energy use, and accelerate prototyping without extensive physical builds. The adoption of lightweight composite materials in car bodies and underframes has achieved weight reductions of 15-20%, improving and extending range on powertrains. Recent developments reflect a push toward amid regulatory pressures. In the , green mandates under the and the 4th Railway Package are accelerating the phase-out of pure-diesel operations, with studies estimating that and battery-powered multiple units could replace up to 30% of diesel fleets on non-electrified lines by 2030. has initiated pilot projects for fuel cell DMUs, such as the hydrogen-powered urban train, to test extended-range zero-emission capabilities on suburban routes. In , battery-hybrid developments aim to reduce diesel dependency in remote networks by 2025. Market forecasts indicate a contraction in the global DMU sector, with the market valued at approximately USD 1.1 billion in 2025 and projected to decline at a (CAGR) of -9.1% through 2033, driven by widespread in developed regions. In and , pure-diesel DMU production is waning as operators prioritize and alternatives to meet emission targets, potentially halving new diesel unit deployments. Conversely, the Asia-Pacific region is expected to account for a significant share of new DMU units due to expanding rural and intercity networks where lags. Emerging markets in also contribute to global demand. Challenges in DMU production persist, particularly supply chain vulnerabilities for rare-earth elements used in electric transmission motors and hybrid batteries, which have caused delays and cost escalates in regions reliant on imports from China. Standardization efforts, led by the International Union of Railways (UIC) through technical specifications for interoperability (TSI), aim to harmonize DMU designs across borders, but varying national regulations continue to hinder modular production scalability.

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