Maintain mechanical equipment within a traction and rolling stock system
Overview
This standard identifies the competences you need to carry out corrective maintenance on mechanical equipment within a traction and rolling stock system, in accordance with approved procedures. You will be required to maintain a range of mechanical equipment, such as wheel sets, bogies, suspension, gearboxes, pumps, engines, and equipment, which are working in an integrated system involving two of the following interactive technologies: electrical, fluid power or process controller. The term traction and rolling stock used in this standard applies to passenger, freight and on-track machines (OTM). Where it is relevant these standards also apply to traction and rolling stock that has been fitted with the European Train Control System (ETCS).
You will be expected to isolate and disconnect items and components of the interactive technologies in order to gain access to and remove the mechanical units and components that require replacing or repair. This will involve dismantling and reassembling a variety of different types of assemblies and sub-assemblies which, in some instances, may need to be dismantled to component level.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying mechanical maintenance procedures within a traction and rolling stock system. You will know about the integrated technology assemblies and sub- assemblies, and their properties, functions and associated defects, in adequate depth to provide a sound basis for carrying out the dismantling and reassembly process safely and effectively. You will also understand the maintenance methods and procedures used, and their application within the traction and rolling stock system, in sufficient depth to be able to carry out the maintenance activities, correct faults, and ensure that the maintained equipment functions to specification and remains compliant with all standards and regulations. You will also know about the interaction of the other associated integrated technologies and have sufficient knowledge to carry out the maintenance and testing safely and effectively.
You will be required to demonstrate safe working practices throughout.
Performance criteria
You must be able to:
P1 maintain safe working practices and comply with all relevant health and safety regulations, directives, and guidelines
P2 follow the relevant maintenance schedules to carry out the required work
P3 carry out the maintenance activities within the limits of your personal authority
P4 carry out the maintenance activities in the specified sequence and in an agreed timescale
P5 report any instances where the maintenance activities cannot be met or where there are identified defects outside the planned schedule
P6 complete relevant maintenance records and pass them on to the appropriate person
P7 dispose of waste materials in accordance with safe working practices and approved procedures
Knowledge and Understanding
You need to know and understand:
K1 the relevant health and safety regulations, directives, guidelines, and safe working practices and procedures defined by your organisation, as appropriate to the activity and your working area
K2 the isolation and lock-off procedure or permit-to-work procedure that applies to the system(such as electrical isolation, locking off switchgear, placing of maintenance warning notices, proving the isolation has been achieved and secured)
K3 the specific health and safety precautions to be applied during the maintenance activity, and their effects on others
K4 the classification of different voltage levels and the authority requirements for working on them
K5 what constitutes a hazardous voltage/current and how to recognise victims of electric shock
K6 how to reduce the risks of an electric shock (such as insulated tools, rubber matting and isolating transformers)
K7 the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities
K8 the hazards associated with carrying out maintenance activities on an integrated system (such as handling fluids, stored pressure/force, electrical supplies, electrical/electronic interfaces, using damaged or ill-maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks
K9 how to obtain and interpret drawings, charts, specifications, manufacturers' manuals, history/maintenance reports and other documents needed for the maintenance activities
K10 the principles of how the system functions, its operation sequence, the working purpose of individual units/components, and how they interact
K11 the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance
K12 company policy on repair/replacement of components during the maintenance activities
K13 the sequence to be adopted for dismantling and reassembling the equipment, to both sub-assembly and individual component level
K14 methods of removing components that have interference fits (expansion, contraction or pressure)
K15 the techniques used to dismantle/assemble integrated equipment (such as release of pressures/force, proof marking to aid assembly, plugging exposed pipe/component openings, dealing with soldered joints, screwed, clamped and crimped connections)
K16 methods of attaching identification marks/labels to removed components or cables, to assist with re-assembly
K17 the torque loading and locking devices requirements for the maintained mechanical components
K18 methods of checking that components are fit for purpose, and the need to replace'lifed' items (such as filters, seals, gaskets and bearings)
K19 the importance of recording the serial numbers of removed and newly fitted components affecting the rolling stock asset tree
K20 the maintenance requirements for 'lifed', consumable and on condition components
K21 how to make adjustments to components/assemblies
K22 the different types of bearings that are used and their care, handling and fitting procedures
K23 how to check that tools and equipment are free from damage or defects, are in a safe and usable condition, and are configured for the intended purpose
K24 the importance of making `integrity' checks before proving the equipment with the systems supplies turned on
K25 the generation of maintenance documentation and/or reports on completion of the maintenance activity
K26 the equipment operating and control procedures to be applied during the maintenance activity
K27 how to use lifting and handling equipment in the maintenance activity, following safe working practices
K28 the problems that can occur during the maintenance activity, and how they can be overcome
K29 the organisational procedure to be adopted for the safe disposal of waste of all types of material
K30 the extent of your authority and to whom you should report if you have a problem that you cannot resolve
Scope/range
Scope Performance
In carrying out maintenance activities, as applicable to the equipment being maintained, individuals will:
- plan and communicate the maintenance activities to cause minimal disruption to normal working
- obtain and use the correct issue of company and/or manufacturers' drawings and maintenance documentation as well as the correct version of any maintenance software tools required
- adhere to procedures or systems in place for risk assessment, control of substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- ensure the safe isolation and de-pressuring, where applicable, of equipment (such as mechanical, electricity, air or fluids)
- provide and maintain safe access and working arrangements for the maintenance area
- warn others in the maintenance area if they are at risk of injury from the system being tested
- carry out the maintenance activities using appropriate techniques and procedures
- reconnect and return the system to service on completion of the maintenance activities
- dispose of waste items to comply with environmental protection guidelines and ensure the work area remains safe
Appropriate dismantling and re-assembly techniques could be used to deal with the following:
fluid power components:- releasing stored pressure
- chocking/supporting cylinders/rams/components
- disconnecting/removing hoses and pipes
- removing and replacing units/components (such as
- pumps,valves, actuators) electrical components
- isolating the power using correct lock-off communication procedure
- removing/replacing minor electrical components(such as relays, sensing devices, limit switches)
- disconnecting and reconnecting wires/cables
- removing and replacing major electrical components (such as motors,
- switch/control gear)
- removing and replacing wiring supports (such as conduit, trunking, traywork, cable ways, looms)
- process controller components:
- de-activating and resetting program controller
- disconnecting/reconnecting wires/cables
- re-loading software/programs and making data amendments
- removing and replacing peripherals
- removing and replacing input/output interfacing
Types of mechanical equipment, on which maintenance activities are carried out, could include:
- gearboxes
- mechanical structures
- engines
- pumps
- doors
- compressors
- suspension
- bogies
- control valves
- brakes
- fuel tanks
- auto couplers
- other specific mechanical equipment
Types of maintenance techniques carried out, as applicable to the equipment being maintained, include:
- draining and removing fluids
- proofmarking/labelling of components
- dismantling equipment to unit/sub-assembly level
- dismantling units to component level (as applicable)
- replacing damaged/defective components
- replacing all `lifed' items (such as filters, seals, bearings, gaskets)
- checking components for serviceability
- setting, aligning and adjusting replaced components
- tightening fastenings to the required torque
- correct fitting of locking devices
- replenishing oils and greases
- making `integrity' checks before powering up system
- functionally testing the complete system
Types of mechanical components to be replaced/refitted could include the following:
- shafts
- valves and seats
- cams and followers
- pulleys and belts
- couplings
- brakes
- axles
- dampers
- springs
- slides
- gears
- bearing and seals
- chains and sprockets
- levers and links
- clutches
- fitting keys
- locking and retaining devices (such as circlips, pins)
- other specific mechanical component
Maintenance activities may need to comply with the following:
- organisational guidelines and codes of practice
- equipment manufacturer's operation range
- BS, ISO and/or BSEN standards
- company standard operating procedures (SOP's)
- documents such as technical procedures, vehicle maintenance instructions, vehicle overhaul instructions, workshop overhaul standards specifications
Types of paperwork/records that need to be completed and passed to the appropriate people could include:
- job cards
- permits to work/formal risk assessment and/or sign on/off procedures
- maintenance log or report
- company-specific documentation
- electronic records