Replacement components and regeneration of railway pneumatics
We manufacture replacement valves, solenoid valves and cylinders, as well as repair kits for pneumatic components that have been discontinued or no longer have available documentation. The component is functionally, dimensionally and mounting-compatible with the original - without rebuilding the entire system and with a focus on reducing downtime.
When is a railway pneumatic replacement component needed?
In rolling stock and railway machines, many systems operate for years. The problem appears when a component has to be replaced and:
- it is no longer manufactured or the manufacturer has disappeared from the market,
- it has non-standard mounting or an old connection plate,
- documentation is missing, and compatibility with the existing installation is critical,
- the original component has a long delivery time and the machine is out of operation.
In such situations, catalogue replacement often requires rebuilding the system. A mounting-compatible replacement solves the problem without this cost.
What we recreate - replacement components and repair kits
Sub-base mounted and directional control valves
Replacements for sub-base mounted valves, including G1/2 railway versions, and directional control valves, with the original plate, hole spacing and ports maintained.
Solenoid valves
Replacements for solenoid valves, including types discontinued from production - for example, the LTE series as a replacement for ŁUCZNIK solenoid valves. See the case study below. Coil voltage and mounting method are selected according to the existing system.
Cylinders and repair kits
Recreation of special pneumatic cylinders and repair kits, including seals and moving elements, for the regeneration of existing railway cylinders.
Filters and filter-regulator units
Filters, filter-regulators and series 58 FR units in railway versions - as recreated components or replacements for discontinued subassemblies.
Case study: replacement for ŁUCZNIK solenoid valves - LTE series
Problem: the customer operated an application with ŁUCZNIK-type solenoid valves with a characteristic plate-mounted design. Several dozen units were already faulty, and the valves were no longer manufactured. Replacing them with different components would have required rebuilding the plates and related subassemblies - a significant cost and downtime.
CPP PREMA solution: a technical and economic analysis showed that recreating the design was less expensive than rebuilding the entire system. We designed and manufactured LTE series solenoid valves, dimensionally and mounting-compatible with the old ŁUCZNIK valves. The solution became a permanent part of the CPP PREMA finished product catalogue.
Do you have an application with ŁUCZNIK solenoid valves or another unsupported valve type?
We will check the possibility of recreating a component compatible with the existing plate - without rebuilding the system.
Ask about a solenoid valve replacementReplacement component or regeneration - which option should you choose?
The choice depends on the technical condition and availability of the component. We check both paths and recommend the more beneficial option for the user.
Regeneration
Recommended when the body and load-bearing elements are serviceable. We replace seals and wear parts, clean the component and complete the assembly. This option is less expensive when wear is limited.
Replacement component
Recommended when the component is unavailable, heavily worn or undocumented. We recreate it with functional, dimensional and mounting compatibility - with the possibility of minor improvements, such as improved sealing.
How does component recreation work?
Analysis
Photos, dimensions, markings, diagram and component mounting method.
Path assessment
Regeneration, catalogue adaptation or a special replacement component.
Documentation
Structure, catalogue number and manufacturing technology.
Production
Component manufacturing, implementation support and further service assistance.
Do you have a component with no available replacement?
Send a photo, dimensions, markings from the body or nameplate, and a description of the function. We will check whether regeneration, a repair kit or a special replacement component will be the better option.
Send a technical enquiryProjects - replacement components and repair kits
Selected work for customers from the railway sector.
| Customer | Scope of work | Component / type |
|---|---|---|
| Railway infrastructure manager | Quotation for a repair kit and replacement cost for a pneumatic cylinder | Repair kit for cylinder 18.1338 |
| Rolling stock diagnostics | Cost update for a blocked cylinder | Cylinder 18.1338, D80x170 / D50x25 |
| Supplier / integrator | Development and assignment of a catalogue number for an FR unit in railway version | ZFR G1/2 filter-regulator unit, series 58 |
| Parts supplier, DE | Delivery of a filter element for a railway system | Filter 58.0011 |
| Rolling stock maintenance facility | Assessment of the production of subcontracted parts and valves according to the DIN 5588 system | Valves from the manufacturer's product range |
What data should be sent for a replacement quotation?
You do not need full documentation. In many cases, photos, dimensions and a description of the function are sufficient.
- Photo of the component It shows the type, mounting method, ports and technical condition.
- Markings from the body or nameplate They help identify the version, series and coil voltage.
- Dimensions or sketch They make it possible to verify the mounting compatibility of the replacement.
- Pneumatic diagram It shows the function of the component in the system.
- Vehicle or machine Typical requirements for a wagon, track machine or auxiliary system.
Why choose CPP PREMA for replacement components and regeneration?
Mounting compatibility
We recreate the component so that it fits the existing plate, ports and stroke - without rebuilding the system.
In-house engineering facilities
Analysis, documentation and production in one place - from a sample or photo to a finished component.
Certificates and railway qualifications
ISO 9001:2015 (TÜV), certificate of the Rail Vehicles Institute “TABOR” and CNTK certificate accepted by the German Federal Railway Authority (Eisenbahn-Bundesamt).
Shorter downtime
The priority is to quickly restore the vehicle or machine to service while maintaining function and safety.
FAQ - replacement components and regeneration of railway pneumatics
What is the difference between a replacement component and regeneration?
Regeneration is the repair of an existing component, including replacement of seals and wear parts, when the body is serviceable. A replacement component is a new part recreated according to the original when the component is unavailable, heavily worn or undocumented.
Do you manufacture replacements for discontinued solenoid valves?
Yes. We analyse the possibility of manufacturing a solenoid valve replacement, including types no longer available on the market, with coil voltage and mounting method selected for the existing system.
What if I do not have documentation for the old component?
In most cases, photos, dimensions, markings and a sample component are sufficient. On this basis, we recreate the documentation and prepare a replacement.
Will the replacement fit the existing plate and mounting arrangement?
Yes - this is the basic assumption. We recreate the component with dimensional and mounting compatibility, maintaining the connection plate, hole spacing, ports and stroke.
How long does it take to manufacture a replacement or repair kit?
The lead time depends on the component and the scope of work. After verifying the data or sample, we provide the time required for documentation and production.
What data should be sent for quotation?
A photo of the component, markings from the body or nameplate, dimensions or a sketch, pneumatic diagram and the type of vehicle or machine.
Send the component for quotation
Do you have a railway valve, solenoid valve or pneumatic cylinder with no available replacement? Describe the application and send the available data. CPP PREMA will check the possibility of regeneration, a repair kit or manufacturing a replacement compatible with the existing installation.