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Locomotive ­modernisation. SBB Passenger Division Operating – your partner for rolling stock ­modernisation.


A vital factor in the success of your rail operations is your rolling stock.


Locomotive modernisation. Our core competencies at a glance.


Locomotive modernisation in the Bellinzona works. Take the modernisation of an Re 420 as an example.


Quality for our customers.14 Our certifications.

A vital factor in the success of your rail o ­ perations is your rolling stock.

The rolling stock you employ is an essential ingredient in the success of your passenger and freight ­operations. It needs to be safe, reliable and available. The locomotive is particularly important: if it isn’t running, the train won’t run. Many railway companies rely on locomotives they have been using for years. If they are well-maintained, they will carry out their daily task of pulling trains across the rail network. However, with advances in ­technology, these reliable locomotives do not necessarily still satisfy all the requirements for a 21st century rail vehicle. Locomotive owners are faced with a difficult decision. How long will the well-tried and tested locomotive be up to the job? Should one replace it and buy a new one? There is an alternative: modernisation – extending the vehicle’s life by another 20 years! Learn more about locomotive modernisation and the service we can offer you. Convince yourself that there is a genuine alternative to buying new rolling stock.

Felix Hauri Head of the Bellinzona works


Locomotive modernisation. Our core competencies at a glance.


Engineering. Engineering services provide the foundation for properly executed, high-quality modernisation work: • Drawing up work instructions • Engineering auxiliary equipment for modernising vehicles and components • Training courses for employees • Technical obsolescence management • Document management Component reconditioning. When reconditioning components, we restore technical systems and assemblies to full working order as part of a modernisation programme:



Disassembly Condition analysis

Overhaul Replacement of defective parts

Functional testing

If equipped with the same functionality as a new part, reconditioned com­ponents provide an interesting financial alternative to the purchase of new c ­ omponents or complete systems. Modernisation. Our rolling stock modernisation programmes can extend vehicle life by 20 years. For example, we overhaul the principal components and systems, install new systems or replace the electrical wiring in its entirety. The work we carry out will maintain and increase the value of your vehicles; and it is tailored solely towards meeting your individual needs.



Locomotive modernisation in the Bellinzona works. Take the modernisation of an Re 420 as an example.


Modernised locomotives for the Zurich S-Bahn – the project in brief. As part of the modernisation of the Zurich S-Bahn, the current double-deck commuter trains’ intermediate coaches are being replaced with new low-floor ­double-deck coaches. These 2nd class intermediate coaches will then be modernised, after which they will run during peak hours in combination with two ­similarly upgraded Re 420 locomotives. This will require an urgent overhaul and extensive alterations to these roughly 40-year-old locomotives.


Number of vehicles • 30 locomotives Objectives

• Equipping the vehicles for 2-locomotive use together with 6 to 10 double-deck coaches at peak times

Scope of the work

• • • •

Refurbishment and value retention New multiple unit control type Vst 6c Integration of all systems for emergency braking Integration of the customer information system and of video surveillance, ­including implementing interfaces to the operating terminal in the locomotive • Overhaul of all main components and systems • Replacement of all high-voltage and control current cabling • Replacement of the speed measurement system with integral safety systems and trip data recording • Retrofitting the compressor unit with an air dryer and an automatic water and oil separator • Electro-pneumatic brakes to control the intermediate coaches and ­loco­motives • Increased ride comfort (electric windscreen wiper motors, driver’s seat with air suspension, armrests and headrests, improved acoustic insulation for driver’s station, new guide for easier operation of the side windows) • Improved operating safety by retrofitting a rear-view mirror on the driver’s side • New ergonomic fittings for the driver’s station • Replacement of the front light units with modern LED lights including lights at the rear of the train • Fitting an operating terminal for the customer information system • Repainting • Installing all control functions for double-deck coaches, in particular brake control, door control, emergency brake request system, and monitoring and fault indicators for technical systems • Handbrake monitoring system with drive-off lock • New wide, trapezoidal buffers with Nylatron plate on one side • New current collectors with breakage and impact protection • New powerful battery charger



S -10

Schnellzug Zürich HB Uster

Re 420 91 85 0 420 101-6

Ä Re 420 LION.

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Schnellzug Zürich HB Uster

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Schnellzug Zürich HB Uster

The Re 420 locomotives will be modernised in accordance with a time-phased production ­system. Nine steps will see the 40-year old vehicle’s interior revivified and its exterior re-styled. The throughput time for each vehicle is 19 weeks.


ì Step 1: Locomotive arrival and disassembly • Remove bogies and traction motor • Completely disassemble the underbody • Disassemble all electrical components • Disassemble all power and control current cables • Disassemble the roof • Disassemble the drivers’ stations • Thoroughly clean the locomotive body frame and ­underbody • Receive supplies of materials • Allocate components for reconditioning

ì Step 2: Initial cleaning • Carry out deep cleaning of the underbody


ì Step 3: Rust treatment, repairs and ì mechanical alterations • Treat rust and carry out repairs to: ·· Roof ·· Windows ·· Front end walls ·· Locomotive body frame ·· Subframe • Make necessary mechanical alterations for use during peak periods • Survey the locomotive body frame • Make mechanical alterations to driver’s consoles

Step 4: Second cleaning • Clean locomotive body frame interior • Dry it off • Prepare for painting • Completely clean all air lines


ì Step 5: Painting (interior, roof and locomotive subframe) • Sand down bodywork • Apply rust inhibitor and noise prevention paint to subframe • Paint engine compartment • Paint subframe • Paint roof • Paint drivers’ stations

ì Step 6: Final assembly • Final assembly of power and control current cables ·· Run and fit the power cables ·· Run and fit the current control cables • Final assembly of overhauled components ·· Reverser switch and brake coils ·· Electronic and pneumatic components in the engine compartment ·· Transformer and step switch ·· Subframe components ·· Bogies ·· Roof

• Final assembly of modified/new components ·· Drivers’ consoles ·· Emergency braking system ·· Windscreen wipers ·· Multiple unit control type Vst 6c ·· UIC plug connection, 18-pin ·· Central equipment cabinet ·· Customer information system ·· LED headlights ·· Air drier and separator ·· Current collector


ì Step 7: Painting (locomotive body exterior and finishing) • Fill and smooth • Clean with compressed air • Prepare for painting • Paint body exterior (primer and paint) • Add lettering and wrapping • Final cleaning ì Steps 8 and 9: Commissioning and acceptance Commissioning takes place in three stages: • Static tests • Dynamic tests • Test runs on the route

Activities include: • Test bench • Testing the train protection systems • Checking the quality of the work • Operational tests • Test runs • Route testing • Document review • Handing over the locomotive to operations


Quality for our customers. Our certifications.


We set value on production quality. Our management system supports employees with systematised processes and sequences. We have a number of certifications: • ISO 9001 quality management system certification • ISO 14001 environmental management system certification • OHSAS 18001 occupational health and safety management system certification • Certification of the risk management system to ISO 31000 • Certification of the risk management system to ONR 49001 • Swiss Tourism Seal of Quality, Level III • ISO 3834-2, EN 15085-2 welding quality assurance certification • Certification by the Union of Private Goods Wagons Companies (VPI) Our processes and working procedures are audited regularly: • By our own department for Risk, Safety, Quality and Environment • By the Swiss Association for Quality and Management Systems (SQS) • By the Swiss Federal Office of Transport (FOT) • Regular system inspections by the Swiss National Accident Insurance Fund (SUVA).

Valid from June 2013

SBB AG Passenger Operating Sales Bellinzona works Viale Officina 18 6500 Bellinzona Switzerland Phone +41 51 227 66 11 Fax +41 51 227 67 97

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