Wabtec MK4 Bogie Overhaul Case Study

Wabtec MK4 Bogie Overhaul Case Study
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Wabtec UK

Mark 4 Bogie Overhaul

Mark 4 coach rolling stock has transported millions of people since it was introduced as part of the InterCity 225 trainsets in 1989. Purpose-built for longer- distance services on the then newly-electrified East Coast Main Line, 302 Mark 4 coaches – there were 314 built in total – are still in service some 31 years later. They are under the ownership of Eversholt UK Rails Group, which leases them to London North Eastern Railway, Transport for Wales and Grand Central. The Mark 4 passenger fleet, which has seven different vehicle types, mainly operates with the 125mph Class 91 electric locomotive and Mark 4 Driving Van Trailer.

In 2006, Eversholt (HSBC Rail at the time) awarded Wabtec Rail a long-term contract worth $140m to overhaul all bogies for Eversholt fleets, including the Mark 4 bogies. The initial contract term was for 10 years, which was unheard of at the time in the UK rail industry after-market but Eversholt wanted to commit to a long-term partnership with a bogie overhauler to build collaboration. The 10-year bogie contract was initially for circa 6,000 bogies for 11 different fleet types and was later extended for the majority of Eversholt fleets.

In 2006, Eversholt also awarded Wabtec Rail a Class 91 locomotive overhaul contract and in 2009 they awarded Wabtec Rail the IC225 fleet heavy maintenance contract for both vehicles and bogies, which comprised of OH1 and OH2 exam cycles. This further developed the collaborative partnership that the companies had established.

The Deliverables

IC225 Vehicle maintenance was carried out in Doncaster and the beat rate was consistent with around 20 bogies completed per month throughout.

The component and wheelshop areas of the business supported the contract by overhauling the bogies’ subcomponents, while the component and HVAC departments were also involved undertaking work on battery boxes, brake frames and air conditioning units.

To date, Wabtec Rail has overhauled nearly 2,500 Mark 4 bogies, 5,000 Mk4 wheelsets and 15,000 brake callipers and actuators.

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