Cutting-edge service and road rail vehicles

Facility enhancements

Along with an expanding product line and service offering, AJH continues to improve its facilities. A 1,100 m² assembly workshop was added in 2021, with the existing workshop converted into a dedicated fabrication area. In late 2025, a new 900 m² site was acquired adjacent to the existing site. This new unit is now used as a dedicated store to improve logistics on-site, with additional heavy fabrication bays set up in the old stores. The entire workshop area has also recently been fitted with a high-efficiency infrared heating system, complementing the existing high-capacity solar panel array, reducing CO² emissions from heating by 13-fold.

Product developments

With a focus on improving rail plant efficiency, AJH has developed solutions for electric-hybrid conversion and for integrating Remote Condition Monitoring (RCM) and condition-based maintenance. These systems are available on all AJH products, and as aftermarket upgrades to OTP, PTMP, civils plant and OTMs.

Electric drivetrains

With battery and electric drivetrain technologies becoming sufficiently mature for adoption in mobile machinery, AJH has been developing engineering solutions to leverage them. The first is a plug-in hybrid conversion kit, initially fitted to self-propelled MEWPs but with potential for use across a wide range of rail plant. In the case of MEWPs, the system is used to improve efficiency, but it can also serve as a power boost for running high-power attachments, such as piling heads on excavators.

The parallel hybrid configuration, with the electric motor positioned between the existing engine and hydraulic pump, avoids the cost and complexity of additional hydraulics. The system also allows tri-mode operation with electric, diesel and hybrid drive, all selectable by the user. 

The biggest cost-saving potential comes from plugging the machine in to charge and then working in electric mode. However, operating in hybrid mode significantly reduces fuel consumption compared to diesel-only operation. For the current MEWP application, the battery is sized to provide a full shift on electric power, and this has been validated with in-service power monitoring.

IoT, RCM and predictive maintenance

As standard, AJH installs an Internet of Things (IoT) system on all new machines. This gives the machine owner remote access to all the relevant data available in the machine’s control system. Information available includes fluid levels and temperatures, DPF regen information, working and idle times, location and fault and error codes. AJH has designed the control system and online customer portal to interface with the engine control system and, where fitted, the InTeEx RCI. This gives the user access not just to the rail conversion data, but also to the host machine and RCI data.

This remote access should significantly improve the machine owner’s operational efficiency. By providing automatic alerts when levels move outside normal thresholds and making error codes available remotely, the customer will be aware of potential issues before they manifest as a service-affecting fault. Additionally, AJH can remotely access both the rail control screen and the InTeEx RCI screen. This means that within minutes of a call to AJH’s service centre, a technician can begin diagnosing the issue and advising the operator on the best course of action. Should on-site support be required, the fitter will arrive with much of the diagnosis already complete.

Optionally, AJH can provide enhanced remote condition monitoring through the online customer portal, enabling predictive maintenance. Oil and fuel quality sensors track contaminants and mechanical characteristics of fluids. The sensor then outputs a quality number and an estimated number of days until the next oil change. Not only does this ensure that oil is changed only when required, but the AJH system's algorithms will also detect anomalies in decay rates and warn machine owners of issues long before they lead to a service-affecting fault.

Vibration sensors can also be fitted to critical components, such as wheel bearings for on-track machines. These sensors are designed specifically for monitoring rotating or

reciprocating parts, and filter out superficial frequencies, allowing the AJH software to

focus only on vibrations that indicate potential issues. Like the oil/fuel quality sensor, this allows bearing maintenance to be optimised and detects issues long before the bearing fails.

Rail plant products

Zagro Unimogs

In partnership with South Cave Tractors (SCT), the UK distributor for Zagro, AJH is now delivering Zagro Unimogs to the UK market. The Zagro Group encompasses Zagro, Zweiweg and Gmeinder Lokomotiven. It also acquired the rights to LH Access Technology’s products in 2022 and currently manufactures the popular LH Unimog MEWP.

Zagro has been designing and manufacturing road/rail Unimogs since 1986, and Zweiweg patented its first road/rail guiding system in the 1970s. While the fundamental railgear design remains faithful to this proven-in-use concept, the product continues to evolve and currently boasts the latest in both road and rail technology.

Due to its close technical relationship with the Unimog manufacturer Daimler Truck, Zagro has been certified as a Unimog Expert Partner. SCT is the only UK-based Unimog bodybuilder with Unimog Partner Status, meaning that Zagro product owners receive the highest-quality aftermarket service available. AJH is able to offer its full suite of complementary systems for installation on Zagro Unimogs, including high-performance movement limiting devices, RCM and measuring pantographs with

electric height and stagger recording.

Rosenqvist

AJH is also working with Pandrol and Rosenqvist to supply and service Rosenqvist attachments and Rail-Mounted Maintenance Machines, including clip drivers, sleeper replacers, sleeper spacers and rail grapples. The clip driver product line includes battery and internal combustion engine options, with lightweight (25kg) manually propelled models right up to excavator-mounted or self-propelled units capable of clipping or de-clipping 40 sleepers per minute. With everything needed to accurately remove ballast, de-clip the rail, and handle the sleeper from the end of an excavator arm, the Rosenqvist sleeper changers make changing concrete sleepers safe and efficient.

Liebherr

Liebherr and AJH have a long history of collaboration, and the current product line has been developed with support from Liebherr earthmoving factories across Europe. With a collaborative working relationship and access to detailed engineering data, AJH can seamlessly integrate rail systems into the base Liebherr machines.

The last six months have seen the release of two new machine models, the RH925 which is a high-performing tracked rail excavator in the 25-tonne class, the baby brother to the R920 offered with both conventional and offset booms (see Rail Infrastructure Issue No: 169) and the AH921 which is a 21-tonne wheeled rail excavator, type 9b friction drive, with zero tailswing and an offset boom. This machine is the replacement for carrying out the drainage works that a Mecalac would have traditionally undertaken. In addition, the AH933 is currently under development.

Overhaul and life extension

A seven-year RIS-1530-PLT upgrade from AJH is not just a recertification exercise; it is an opportunity for a full machine overhaul and life extension. With the high capital investment needed for bespoke road/rail vehicles, it is important to keep them running efficiently and reliably for as long as possible. To this end, AJH has overhaul capabilities including re-hosing, rewiring, line boring and weld repair, reverse engineering and remanufacturing of parts, upgrading control systems, and even fitting whole new railgear systems. Where local emission rules prevent the use of previous-generation diesel engines, AJH can supply, fit, and commission new power packs compliant with the latest Stage V legislation. This work is all supported by specialist suppliers with whom AJH have been working for many years.

Bespoke design and build

With an experienced design team, in-house computer simulation capabilities, on-site fabrication and assembly, a dedicated test and calibration department, and knowledge of product legislation and standards, AJH is fully equipped for turnkey design and manufacture projects. If you have an idea for a product no one currently makes, then AJH can provide you with a bespoke solution. See page 50 for details of a recent AJH project, a towbar for recovering road/rail vehicles using an on-track machine.

Service and maintenance

AJH’s field service organisation is focused on delivering high-quality maintenance and first-time fixes for in-service faults. All maintenance staff are employed directly by AJH, ensuring a high level of staff competence and ongoing competency development. AJH vans are stocked with as many common and critical spares as possible, reducing the need for revisits. The spares carried are also reviewed regularly to ensure they are kept up to date with product developments and improved based on maintenance staff experience.

While other suppliers may offer lower hourly rates, AJH’s service reduces both the number of hours billed to fix a fault and the total machine downtime. This leads to a lower total cost of ownership for the machine and increased value.