Koko (US) / Koko / Koko (UK) (126 episodes, 2008-2013)
Koko (UK) / Koko (US) (109 episodes, 2008-2013)
Wilson (US) / Wilson (104 episodes, 2008-2013)
Wilson (UK) / Wilson / Wilson (US) (94 episodes, 2008-2010)
Old Puffer Pete / Morgan / Irving / Dr. Gosling / Mr. Knot / Building Site Foreman / Cameraman / Emery / Snap / The Photographer (86 episodes, 2008-2020)
Vee / Lori / Karen / Linda / Ice-Cream Customer / Lady / Mayor's Assistant (85 episodes, 2008-2013)
Brewster (US) (81 episodes, 2008-2013)
Brewster (UK) (79 episodes, 2008-2010)
Vee (US) (77 episodes, 2008-2010)
Old Puffer Pete (US) (66 episodes, 2008-2013)
Dunbar (UK) / Chatsworth (UK) / Felix (UK) / Chatswoth (UK) (62 episodes, 2008-2013)
Calley (UK) / Vicki (UK) / The Post Mistress (UK) (51 episodes, 2008-2013)
Emery (US) (53 episodes, 2008-2013)
Emery (UK) (52 episodes, 2008-2013)
Dunbar (US) / Chatsworth (UK) (49 episodes, 2008-2013)
Calley (US) (43 episodes, 2008-2013)
Irving (US) / Action Chugger (US) (43 episodes, 2008-2010)
Koko / Koko (US) (41 episodes, 2020-2021)
Brewster / Brewster (US) (41 episodes, 2020-2021)
Chatsworth (US) (39 episodes, 2008-2013)
Eddie (US) (39 episodes, 2008-2009)
Wilson / Wilson (US) (39 episodes, 2020-2021)
Eddie (UK) (37 episodes, 2008-2009)
Zephie (US) / Zephie (34 episodes, 2008-2013)
Morgan (US) (35 episodes, 2008-2010)
Hodge (UK) (34 episodes, 2008-2013)
Hodge (US) (34 episodes, 2008-2013)
Zephie (UK) (32 episodes, 2008-2013)
Wilson (UK) (31 episodes, 2008-2013)
Harrison / The King of Buffertonia (29 episodes, 2008-2013)
Brewster (UK) / Brewster (UK & US) (30 episodes, 2008-2013)
Jackman (UK) (30 episodes, 2008-2020)
Skylar (27 episodes, 2008-2013)
Hoot (UK) (26 episodes, 2008-2013)
Toot (UK) (26 episodes, 2008-2013)
Toot (US) (26 episodes, 2008-2013)
Hoot (US) (26 episodes, 2008-2013)
Zack (UK) (25 episodes, 2008-2013)
Mtambo (UK & US) / Mtambo / Nurse David (UK) (21 episodes, 2008-2020)
Olwin (UK) (19 episodes, 2008-2013)
Olwin (US) (19 episodes, 2008-2013)
Fletch (UK) (22 episodes, 2008-2013)
Frostini (UK & US) / Frostini (19 episodes, 2008-2020)
Tyne (UK) / Tyne (US) (21 episodes, 2008-2013)
Speedy McAllister / Speedy McAllister (UK) (19 episodes, 2008-2013)
Tyne (US) (21 episodes, 2008-2013)
Vee / Vee (US) (21 episodes, 2020-2021)
Lori (US) (20 episodes, 2008-2009)
Hanzo (UK) (19 episodes, 2008-2013)
Action Chugger (UK) (17 episodes, 2008-2020)
Speedy McAllister (US) / Speedy (US) / Speedy McAllister (UK) (15 episodes, 2008-2013)
Skylar (UK) (16 episodes, 2008-2013)
Howie (UK) (12 episodes, 2008-2013)
Skylar (US) (9 episodes, 2008)
Asher (9 episodes, 2008)
Piper (9 episodes, 2020-2021)
Wilson (Vocals) (9 episodes, 2021)
Decka (UK & US) (8 episodes, 2008-2013)
Cormac (UK) (8 episodes, 2008)
Mayor Pullman (UK) (7 episodes, 2008)
Film Set Assistant (UK & US) / Karen (US) / Director (UK & US) (6 episodes, 2008)
Dr. Ling (UK & US) (6 episodes, 2008-2010)
Dr. Gosling (US) (6 episodes, 2008)
Director (UK) (6 episodes, 2008)
Skipper Stu (UK & US) (5 episodes, 2008-2020)
Piper (UK & US) (5 episodes, 2008-2013)
Pace (UK) / Pace (5 episodes, 2008)
Jackman / Jackman (US) (5 episodes, 2020-2021)
Mayor Pullman (5 episodes, 2020)
Morgan / Morgan (US) (5 episodes, 2020)
Skylar (US) / Skylar (4 episodes, 2008-2013)
Hamish (UK) (4 episodes, 2008)
(4 episodes, 2008)
Russ (UK) (4 episodes, 2008)
Hoot / Hoot (US) (4 episodes, 2020)
Zack (US) (3 episodes, 2008-2013)
Rag Barnstaple (UK) / Mr. Simpkins (UK) (3 episodes, 2008)
Child (UK) (3 episodes, 2008)
Chug Scan / Chugatronic / Flav-O-Matic (3 episodes, 2020-2021)
Koko (UK) (3 episodes, 2020)
Wilson (UK) (3 episodes, 2020)
Brewster (UK) (3 episodes, 2020)
Piper (3 episodes, 2020)
Mr. Mistereoso (UK) (2 episodes, 2008-2010)
Fletch (US) (2 episodes, 2008-2013)
(2 episodes, 2008)
ChugNav (UK) (2 episodes, 2008)
Storm Maker (UK) (2 episodes, 2008)
Child (UK) (2 episodes, 2008)
Ice-cream Customer (UK) / Jenny (UK) (2 episodes, 2008)
Rosa (2 episodes, 2020)
Zephie (US) (2 episodes, 2020)
Toot (US) (2 episodes, 2020)
Zephie (UK) (2 episodes, 2020)
Tai (2 episodes, 2020)
Toot (UK) (2 episodes, 2020)
Vee (UK) (2 episodes, 2020)
Hoot (UK) (2 episodes, 2020)
(1 episode, 2008)
The Inspector (UK) (1 episode, 2008)
Denzil (US) (1 episode, 2008)
Storm Maker (Spanish) (1 episode, 2008)
Action Chugger Movie Announcer (UK) (1 episode, 2008)
Inspector Nichols (US voice) (1 episode, 2008)
Action Chugger Fans (UK) (1 episode, 2008)
Denzil (UK) (1 episode, 2008)
Felix (US) (1 episode, 2008)
Old Puffer Pete (US) (1 episode, 2020)
Piper (1 episode, 2020)
Action Chugger (US) (1 episode, 2020)
LA Kid (1 episode, 2021)