Major overhauls of diesel locomotives

About the Company

Since 2010, Prombudkoliya has been carrying out major overhauls of diesel locomotives of all series — ChME3, TGM3, TGM6, TEM2, TEM18, M62, 2M62, and others. We restore rolling stock to full operational condition, including the locomotive body, diesel engine, transmission, bogies, and electrical systems. All work is performed in accordance with Ukrzaliznytsia regulations and the technical requirements of original equipment manufacturers.

Major overhauls are carried out at our repair facility equipped with test benches for diesel engines, compressors, generators, and brake equipment. Each locomotive undergoes comprehensive diagnostics and quality control at all stages of repair.

Purpose of Major Overhaul

The purpose of a diesel locomotive major overhaul is the complete restoration of its technical characteristics, extension of service life, and improvement of operational reliability. After overhaul, the locomotive service life is extended by 10–15 years, provided regular maintenance is performed.

Main Stages of Major Overhaul

1. Acceptance and Diagnostics

The locomotive undergoes a technical inspection, including testing of control systems, brakes, diesel engine, transmission, and electrical circuits. The scope of repair work is determined, and a defect inspection report is prepared.

2. Complete Disassembly and Cleaning

The locomotive is disassembled into individual units and assemblies. All parts are cleaned and inspected for wear and defects. Components that cannot be restored are replaced with new or refurbished parts in accordance with applicable standards.

3. Repair and Restoration of Assemblies

• Diesel engine: major overhaul, cylinder boring, crankshaft grinding, replacement of pistons, rings, injectors, and bearings.
• Transmission and gearboxes: disassembly, defect inspection, replacement of bearings and gears, verification of shaft alignment.
• Bogies and running gear: replacement of axles, bearings, springs, brake shoes, restoration of axlebox assemblies.
• Brake system: repair of compressors, pressure regulators, pneumatic valves, and full leak-tightness inspection.
• Electrical equipment: inspection of generators, starters, batteries, replacement of worn cables and contacts.

4. Assembly and Adjustment

After repair, all assemblies are integrated into a single system. Adjustment of fuel, cooling, brake, control, and power supply systems is performed. Automation settings and protective devices are calibrated and tested.

5. Testing and Running-In

Each locomotive undergoes running-in at idle and under load. Diesel engine power output, fuel consumption, pressures, temperatures, and system performance are verified. Upon successful testing, a certificate of readiness for operation is issued.

Scope of Work

• Complete disassembly and major overhaul of the diesel engine
• Repair of gearboxes, clutches, shafts, and couplings
• Restoration of running gear and brake systems
• Body repair, painting, and anti-corrosion treatment
• Servicing of generators, starters, and batteries
• Bench testing and running-in with official test reports

Our Capabilities

• Major overhaul of diesel locomotives of all series and modifications
• Full technical support from defect inspection to commissioning
• Test benches and own production facilities
• Original and certified spare parts
• Mobile repair teams for on-site work
• Major overhaul warranty — up to 18 months

Company Advantages

• 15 years of experience in diesel locomotive and engine repair
• Certified specialists and quality control at every stage
• Comprehensive approach: diesel engine, bogies, electrical equipment, body
• Guaranteed restoration of technical performance
• Compliance with Ukrzaliznytsia regulations and ISO 9001
• Long-term reliability after overhaul

Completed Project Examples

Major Overhaul of a TEM18 Diesel Locomotive (Dnipro, 2023)

Complete overhaul of the D49 diesel engine, restoration of bogies, renewal of electrical wiring, and body refurbishment. The locomotive successfully passed testing at rated power and was delivered to the customer on schedule.

Overhaul of a ChME3 Locomotive for an Industrial Enterprise (Poltava Region, 2022)

Major repair of the diesel engine, running gear, and brake system. Painting and replacement of cable routes were performed. The locomotive operated under warranty without any claims.

Major Overhaul of a TGM6A Locomotive (Zaporizhzhia, 2021)

Defect inspection and complete restoration of the power unit, transmission, and electrical equipment were carried out. Running-in tests were completed, and the locomotive was commissioned with an acceptance certificate.

Frequently Asked Questions

How often is a major overhaul required for a diesel locomotive?

A major overhaul is recommended every 10–15 years or after 600,000–800,000 km of operation, depending on operating conditions.

Is phased overhaul possible?

Yes, a component-based overhaul is possible — diesel engine, bogies, electrical systems, or bodywork can be repaired separately.

What documents are issued after overhaul?

An acceptance certificate, test reports, locomotive passport, and warranty certificate are provided.

Do you work with industrial enterprises?

Yes, Prombudkoliya performs major overhauls of diesel locomotives for both public and private enterprises, including industrial and port locomotives.

Submit a Request

Need a major diesel locomotive overhaul? Submit a request, and Prombudkoliya specialists will perform diagnostics, prepare a cost estimate, and complete a turnkey overhaul of your locomotive with guaranteed quality and long-term reliability.