Optimised Wheelset Bearing Maintenance Plan for DB Cargo

DB Cargo and DB Systemtechnik have comprehensively modernised the maintenance strategy for the wheelset bearings of locomotive classes 261 and 265. The objective was to increase safety, cost efficiency and fleet availability over the long term. Through systematic analyses and laboratory investigations, the maintenance interval for wheelset bearings was scientifically validated and legally secured for extension to twice its previous length, while fully complying with all regulatory requirements.

The Challenge: Balancing Safety and Cost Efficiency

Wheelset bearings are critical to safe and reliable railway operations. Previously, maintenance activities were based on conservative manufacturer specifications. The aim of the project was to align maintenance intervals more precisely with actual wear behaviour and real operating conditions, without compromising safety, regulatory compliance or reliability.

To achieve this, the manufacturer’s maintenance plan was converted into an operator maintenance plan and tested, evaluated and adapted within the framework of a pilot maintenance programme (VIHP). This resulted in a data-driven and scientifically validated basis for establishing the new maintenance interval limit. In parallel, additional components such as wheelset gearboxes and bogies were optimised to harmonise maintenance interval limits throughout the running gear system.

Approach and Services

DB Systemtechnik supported the project from analysis through to implementation. The measures included:

Review and optimisation of the existing maintenance plan in consideration of current standards (e.g. DIN EN 17023)
Laboratory investigations, condition assessments, field data analysis and additional examinations at selected intervals
Structured risk analyses and hazard assessments
Legally compliant and standards-compliant implementation and documentation in accordance with DIN EN 17023 and the ECM Regulation (EU) 2019/779

Based on these activities, the maintenance interval limit could be extended. Additional investigations ensure continuous verification of the new intervals, while clearly defined termination criteria guarantee operational safety during ongoing service. The previous limit values were confirmed, and maintenance intervals twice as long were introduced.

Class 265

Results and Practical Evidence

The analyses showed that the wheelset bearings remain in excellent condition even with extended maintenance intervals. All results met the applicable requirements, and damage reports revealed no abnormalities, allowing implementation to proceed without restrictions. As a result, safety was maintained while cost efficiency was improved.

Benefits for DB Cargo

Consistent Safety: Compliance with all applicable standards and regulatory requirements.
Lower Life Cycle Costs (LCC): Reduced maintenance requirements.
Higher Availability: Less downtime thanks to extended maintenance intervals.
Increased Efficiency: Reduced workshop times and maintenance costs.
Transparency & Traceability: Standards-compliant and auditable decision-making basis.
Future Readiness: Data-driven processes for long-term fleet planning.

With this approach, DB Cargo and DB Systemtechnik demonstrate how adapting the maintenance plan can successfully combine safety, efficiency and cost-effectiveness.

Learn More

Would you like to learn more about DB Systemtechnik’s services for the development and optimisation of maintenance plans in accordance with the requirements of DIN EN 17023?

You can find further information on our product page. Drafting and optimisation of regulations

Article: Optimised Wheelset Bearing Maintenance Plan for DB Cargo