Maintain traction and rolling stock vehicle trim and fittings
Overview
This standard identifies the competencies you need to carry out maintenance on traction and rolling stock vehicle trim and fittings in accordance with approved procedures. You will be required to maintain a range of vehicle trim and fittings, such as seats, tables, panels, luggage racks, windows, and cubicles. This will also include the removal and replacement of vehicle trim and fittings to gain access for inspections and other systems maintenance activities. 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 required to select the appropriate tools and equipment to use, based on the operations to be performed and the components to be removed. The maintenance activities will include taking all necessary safeguards to isolate the equipment, support and lift removed and replaced parts, replacing faulty equipment at component or unit level, setting and adjusting replaced components, and leaving the equipment in a safe condition and ready for testing.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying appropriate maintenance procedures techniques and procedures to traction and rolling stock vehicle trim and fittings. You will know about the trim 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 vehicle trim and fittings, 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 systems with the trim/fittings 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 remove and replace the required components, using approved tools and techniques
P7 take suitable precautions to prevent damage to components and the surrounding structure
P8 complete relevant maintenance records and pass them on to the appropriate person
P9 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 maintenance carried out (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 steps to take to secure the vehicle from movement and protect it from other vehicle movement
K5 the classification of different voltage levels and the authority requirements for working on them
K6 what constitutes a hazardous voltage/current and how to recognise victims of electric shock
K7 how to reduce the risks of an electric shock (such as insulated tools, rubber matting and isolating transformers)
K8 how to reduce the risks associated with stored energy systems (such as capacitors, air systems, hydraulic systems and springs)
K9 the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities
K10 the hazards associated with removing vehicle trim and fittings, and with the tools and equipment used (such as lifting and handling, misuse of tools) and how to minimise them and reduce any risks
K11 how to obtain and interpret drawings, charts, specifications, manufacturers' manuals, history/maintenance reports and other documents needed for the maintenance activities
K12 the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance
K13 company policy on repair/replacement of components during the maintenance activities
K14 the importance of recording the serial numbers of removed and newly fitted components affecting the rolling stock asset tree
K15 the procedures for quarantining defective materials and local warranty procedures for repair or replacement
K16 the sequence to be adopted for dismantling and reassembling the equipment, to both sub-assembly and individual component level
K17 the techniques used to remove trim and fitting components from the vehicle, without damage to integrated components or surrounding structure
K18 methods of attaching identification marks/labels to removed components to assist with re-assembly
K19 the torque loading and locking devices requirements for the maintained components
K20 the importance of applying electrostatic discharge (ESD) procedures when working on sensitive equipment or devices
K20 the various mechanical fasteners that will need to be removed and replaced and their method of removal and replacement (such as threaded fasteners, special securing devices)
K21 the various types of electrical connector that are used, methods of unlocking, orientation indicators and locating and locking in of the connections
K22 methods of lifting, handling and supporting the components/equipment during the maintenance activities
K23 the importance of ensuring that any exposed electrical connectors or pipe ends are covered/protected
K24 the need to label and store components that require repair or overhaul and to check that replacement components have the correct part/identification markings
K25 how to reconnect trim and fittings into the vehicle (such as the use of gaskets/seals and jointing/sealing compounds; ensuring correct tightness of pipe fittings, eliminating stress on pipework and cable connections; carrying out visual checks of all components)
K26 how to make adjustments to components/assemblies (such as seats, mechanisms, settings travel and working clearance)
K27 why electrical bonding is critical and why it must be both mechanically and electrically secure
K28 the generation of maintenance documentation and/or reports on completion of the maintenance activity
K29 the equipment operating and control procedures to be applied during the maintenance activity
K30 the problems that can occur during the maintenance activity and how these can be overcome
K31 the organisational procedure to be adopted for the safe disposal of waste of all types of materials
K32 the extent of your own authority and to whom you should report if you have a problem that you cannot resolve
Scope/range
Scope Performance
During the maintenance activity, 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 of equipment (such as mechanical, electricity, air or fluids)
- provide and maintain safe access and working arrangements for the maintenance area
- carry out the maintenance activities using appropriate techniques and procedures
- reconnect and return the vehicle trim and fittings 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
Types of vehicle trim and fitting equipment systems on which components may be removed and replaced include:
- passenger fittings
- cab fittings
- vestibule panels
- berth/bunk fittings (sleepers)
- luggage and storage systems
- toilet equipment
- panel systems
- auxiliary equipment
- catering equipment
- decorative trim and coverings
- safety equipment
- other specific vehicle components
Types of components to be removed/replaced could include:
- Major cabin equipment and furnishings:
- seating (such as driver, attendant, passenger)
- windows (such as side lights, windscreen)
- tables
- bunks
- entertainment equipment
- flooring (such as carpets, vinyl)
- food preparation equipment
- water heaters
- fridges
- beverage machines
- panels (such as ceiling, side, floor, soft panels)
- gangway bellows
- screens/dividers/removable bulkheads
- sanitary units and fittings
- equipment consoles
- storage units (such as luggage racks, overhead storage)
- other specific major components
- Other vehicle equipment and furnishings:
- fire extinguishers/blankets
- galley storage boxes
- seat covers
- hard trim
- emergency escape/survival equipment
- safety notes
- footplates
- hand rails
- waste bins
- advertising frames
- pipes and hoses
- curtains/blinds
- medical equipment (such as first aid boxes)
- other specific components
Types of maintenance activities carried out could include:
- disconnecting electrical connections (where appropriate)
- proofmarking/labelling of components
- ensuring that any part dismantled components are secure/supported
- applying and removing covering/protection to exposed connectors, components, wires, pipework or vents
- labelling (and storing in the correct location) components that require repair, overhaul or temporary storage
- checking components for serviceability
- replacing damaged/defective components
- positioning and aligning replaced components
- making mechanical connections
- making electrical connections (where appropriate)
- tightening fastenings to the required torque
- setting, and adjusting replaced components (such as travel, working clearance)
- securing components using mechanical fasteners and threaded devices
- applying fastener locking methods (such as split pins, wire locking, lock nuts)
Maintenance activities may need to be completed in accordance 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