How to prolong the life of the railway

coupler system and make it safe up to

the next overhaul period?
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Welcome!

Zoltan Juhasz Magnus Andersson

Global Senior Sales Engineer Dellner Service Global Support Manager Dellner Service
Presenter Moderator

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Introduction

Introduction
• Dellner Background
• Preventive Maintenance
• Condition Assessment
• Specifying a Customized Overhaul
• Carrying out Overhaul
• Benefits of Working with Dellner
• Questions & Answers
• Short survey

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Dellner Background

Dellner Background
22 production and
Company HQ in Falun,
service subsidiaries in
Sweden
16 countries

Global market leader in

More than 1100 producing Products for all train
employees Train Connection applications
Systems

Dedicated solutions for

Excellent global after
train builder, operators
sale support
and mainteiners

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Dellner Background

Dellner Background

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Dellner Background

Train Connection Systems

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Automatic Coupler

Automatic Coupler

Overhaul
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Preventive Maintenance

Preventive Maintenance

60 to 120 day service interval

Annual service interval

“Heavy” maintenance not until the 8-10 year overhaul interval

Typically the first and third overhaul are a “light overhaul” with more scope
included at the 2nd overhaul (a.k.a. the “mid-life overhaul”)

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Condition Assessment

Condition Assessment

Functional
How to start? Teardown Inspection NDT
testing
Report

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Condition Assessment

Disassembly

The first step to start the condition assessment is to schedule the

teardown and evaluation 1 year before overhaul is due to start.

Ideally two couplers can be provided which have condition

representative of the majority of the fleet.

The coupler will be disassembled down to primary components.

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 Inspection

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Condition Assessment

NDT
• Non-destructive testing is recommended to be
performed as part of the condition assessment on the
main load carrying components of the coupler.
• First the paint is stripped, and then mag-particle
testing is used for ferrous parts, and liquid penetrant
testing for non-ferrous parts.
• Checking for linear indications indicative of any cracks.
• Cracks are not common, but it is relatively inexpensive
to perform and puts passenger safety first.

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Condition Assessment

Functional Testing
Subassemblies with specific functional requirements
would be tested if applicable:
• Pneumatic cylinders for electrical coupler
actuation or automatic uncoupling.
• Electrical linear motors for the same functions.
• Valves, electrical heaters, etc.
• Regenerative crash energy management systems
tested to ensure compliance.

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Condition Assessment

Review report with customer

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Overhaul Specification

Overhaul Specification

Bill of material identifies scope for every part

Overhaul description acts as the specification

Mandatory and On-Condition parts defined

Establish stock levels

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Overhaul Specification

Bill of Material

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Overhaul Specification

Overhaul Description

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Automatic Coupler

Automatic Coupler

Overhaul
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Mandatory parts

Mandatory vs On-Condition Parts

Mandatory Parts
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On-Condition parts

Mandatory vs On-Condition Parts

On-Condition Parts
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Overhaul Specification

Establish Stock Levels

• Text? – see notes

Establish Stock Levels

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Carrying out Overhaul

Carrying out Overhaul

Coordinate Evaluation
Mechanical Paint Functional
returned and NDT Repainting Rebuild Final Testing
inspection stripping Testing
material disassembly

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Carrying out Overhaul

Coordinate Returned Material

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Carrying out Overhaul

Evaluation and disassembly

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Mechanical Inspection Carrying out Overhaul

Mechanical Inspection
• Text

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 Paint Stripping
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Carrying out Overhaul

NDT

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Carrying out Overhaul

Repainting
Before overhaul After overhaul

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Carrying out Overhaul

Rebuild

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 Final pre-delivery testing
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Carrying out Overhaul

Quality doc package

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Carrying out Overhaul

Ship to customer

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Benefits with Dellner

Benefits of coupler overhaul with Dellner

One knowledge source Upgrade or repair not replace Minimize costs Coupler's life time Dellner engineering
extension know-how

Flexible Concepts Availability of Dellner Couplers updated to Highest quality service for Dellner warranty
genuine parts the latest technology all type of couplers

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Q&A

Questions & Answers

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 For further information please visit
www.dellner.com

COPYRIGHT
All rights reserved – Dellner Couplers AB.
No part of this publication may be reproduced or transmitted in any form or by any means or stored in any retrieval system of any nature without the prior written permission, except for
permitted fair dealing under the Copyright Act, or in accordance with the terms of a license issued in respect of photocopying and/or reprographic reproduction.
Application for permission for other use of copyright material including permission to reproduce extracts in other published works shall be made to Dellner AB. Full acknowledgement of
author, publisher and source must be given.