Swietelsky UK has long been at the forefront of railway maintenance, ensuring that its fleet of On-Track Machines (OTMs) remains in top condition. As part of its meticulous asset management regime, the company embarked on a significant milestone in 2024—the comprehensive 10-year overhaul of 928001, a high-performance tamping machine that has played a crucial role in track maintenance since entering service in 2014.
A Decade of Service and a New Beginning
Having logged an impressive 18,500 hours of operation and executed over 2.5 million tamping inserts, 928001 has been an invaluable asset in maintaining the UK rail network. Recognizing the need for a major refresh, Swietelsky meticulously planned an extensive overhaul, ensuring that the machine could continue delivering top-tier performance for years to come.
Planning began in April 2023, with a detailed scope of works and a Gantt chart mapping out the overhaul timeline. This allowed the dedicated team to procure the necessary spare parts in advance. Leading this ambitious project were Andy Brown (Overhaul Supervisor), alongside Stuart Mathison (Chargehand), with skilled engineers Dave Davies, Adam Jackson, Samual Jackson, and fourth-year apprentice Alana Rowbotham.
Phase One: Preparing for Overhaul
In August 2024, the first major step in the overhaul was completed—a new Cat C27 engine was fitted in anticipation of the December start of full-scale maintenance. The machine completed its final active shift on November 23, 2024, before transiting to Swietelsky’s Worksop depot, where the overhaul commenced in earnest.
Disassembly and Inspection
The first stage of the overhaul involved meticulous disassembly:
- The rear section of the machine was separated to inspect and renew interconnecting pins and bushes.
- The machine was jacked up, and all bogies were removed for detailed inspection and refurbishment.
- Trolley wheels were taken off to facilitate the renewal of stub axles, bearings, and split flanges.
- Roof sections over the power car were dismantled, allowing the removal of the generator engine, pump drive gearbox, and hydraulic pumps, along with all associated hydraulic hoses.
- Carden shafts were extracted and sent off for testing and balancing.
- Hydraulic traction hoses were examined, with findings recorded to refine Swietelsky’s hydraulic hose renewal policy.
- The pump drive gearbox underwent a complete rebuild, including the installation of new bearings and seals.
- The bogies were stripped down to the frames, removing all brake rigging, traction motors, King pin cups, side bearers, suspension springs, and brake cylinders. The frames were lifted off wheelsets and placed on trestles for thorough inspection and measurement for any twisting.
- Wheelsets were subjected to Ultrasonic Axle Testing (UAT) to ensure they met safety and operational standards.
Phase Two: Reassembly and Upgrades
Once inspections and component overhauls were completed, the reassembly process began:
- Bogies were refitted onto wheelsets and reassembled with new pins, bushes, traction motors, brake cylinders, King pin cups, and side bearers. Suspension springs were measured and tested for height and integrity.
- New King pin domes were installed on the underside of the machine to accommodate the bogies.
- A new Kubota engine was installed for the generator, while the old engine was repurposed for apprentice training.
- The rebuilt pump drive gearbox was refitted alongside new hydraulic pumps.
- High-pressure traction hoses were replaced with OEM Airoquip hoses, following Swietelsky’s stringent hydraulic hose policy.
- Plasser engineers integrated the latest MCO system hardware, enabling real-time remote monitoring of multiple machine functions, aligning 928001 with the newer 09 4x4 tampers.
- The bogies were reattached, the machine was lowered back onto them, and all underslung components—including hydraulic and pneumatic brake hoses—were securely refitted.
- The interconnecting beam between the main body and power car was reinstalled, and roof sections were returned to position.
- The overhaul concluded with a full system test, including the legally required 12-month brake test.
Final Touch(Part 1): A Fresh Look
With all mechanical and functional updates complete, 928001 was transited from Worksop to Loram’s Derby workshop on March 4, 2025, where it received a full respray in Swietelsky’s new corporate livery.
Looking Ahead
This extensive overhaul ensures that 928001 will continue to play a pivotal role in track maintenance for years to come. The dedication and expertise of Swietelsky’s engineering team have not only extended the machine’s lifespan but also enhanced its efficiency, reliability, and safety. With cutting-edge upgrades and a fresh coat of paint, 928001 is now ready to return to service—stronger, smarter, and more resilient than ever.
Swietelsky’s commitment to proactive maintenance and innovation reinforces its position as a leader in railway engineering, ensuring a better, safer, and more efficient rail network for the future.
Image credits: Swietelsky
