UNDERFRAME

U01 Rail bogies – check *

U02 Underframe – examine * * *

U03 Ballast weight – check security * *

U04 Retaining bolts and pins – check *

U05 Coupling and tow bar – examine * * *

U11 Rail bogies – examine * * *

U12 Rail bogies and underframe – clean * *

WHEELS

W01 Road wheel nuts and tyres – check *

W02 Rail wheels – check * *

W12 Rail wheels and bearings – examine * *

W21 Road wheels and tyres – examine * * *

W22 Rail wheels back-to-back – gauge *

Table 12 Maintenance summary (star chart) (selected sections only)

The star chart gives a summary of the tasks to be performed and when. The actual detail of what is to be performed should be set out elsewhere in the maintenance documentation.

9.4

Particular requirements

9.4.1

Brakes

9.4.1.1 The maintenance plan shall include a statement of the brake test procedure. The brake test procedure shall be assessed as part of the engineering acceptance process.

9.4.1.2 As a minimum there shall be an annual brake test, which shall detail the requirements for all the brake systems fitted.

The manufacturer should initially state in the maintenance plan the frequency for brake test, which as a minimum should be annually. Some vehicle types, for example MEWPs, and some designs of brake system, could require more frequent testing. The plan is able to be amended as subsequent service experience is gained, (see also 3.4.1.7 c)).

9.4.1.3 A vehicle capable of towing other vehicles shall have brake pressures tested at the inter vehicle connecting point and figures recorded at least annually.

It is recommended that in addition to ensuring that a vehicle stops within the required distance, or the brake force is correct, a statement should be included to the effect that if the stopping distance increases, or force decreases, by more than 10% over previous results, the reasons should be investigated and corrected.

Parking brakes on trailers should be tested by applying a pulling or pushing force and checking that the wheels do not rotate; for most 10 mph (16 km/h) trailers this force is equivalent to 6% of the total weight of the loaded trailer. Parking brakes on towing vehicles should be tested as instructed by the manufacturer. It is permissible for this to be a pull test if the manufacturer states that this is sufficient.

9.4.2

Rail wheels

9.4.2.1 Each maintenance plan shall include a statement of the maintenance requirements for wheels. This shall include the limits shown in Tables 4 and 5, and Figures 12 and 13. 9.4.2.2 Wheels shall be maintained so that they are safe to operate under all normal conditions of

wear, suspension condition, vehicle loading and speed and that the geometry of the wheel is compatible at all times with the standard rail and track geometry.

The manufacturer may set tighter limits than those shown in Tables 4 and 5, but the maintenance plan should be designed to not allow an exceedance of the figures in the tables.

It is recommended that information is provided to enable readers to understand the various forms of wheel defects. For example, the result of metal migration down the flange can be similar in appearance to a structural crack. Migration does not affect the integrity of the wheel, whereas a crack does.

9.4.3

Road wheels and tracks

9.4.3.1 Each maintenance plan shall include a statement of the maintenance requirements for road wheel tyres where fitted. As a minimum this shall include requirements to check tyre pressure, wear and condition, road tyre to rail wheel / rail head contact pressure and compatibility between tyre types.

This is important for 9C vehicles, as it has been demonstrated that poor tyre condition and incorrect pressure can have a significant effect on braking performance. On both 9B and 9C vehicles tyre condition will also affect the traction capability. Tyre type mix, excessive tread wear, appreciable

variations in tread wear between tyres driving the rail wheels and excessive tread damage are all significant factors.

9.4.3.2 The maintenance plan shall detail the permitted tyre types and tyre type combinations, and the requirements / adjustments needed following tyre change. The information included in the plan, shall as a minimum, include the following where applicable:

a) Squash – limits and method of measuring. b) Tyre pressures.

d) Tyre identification and acceptable alternative requirements.

e) Matching replacement tyres across machine with tyres already fitted.

It is recommended that following a tyre change a functional brake test is carried out immediately before further use and a brake stopping distance test at the earliest opportunity.

9.4.3.3 The maintenance plan shall detail the permitted wear limits of tracks, as required by 6.1.4 b).

9.4.3.4 The maintenance plan shall include the detail and frequency for checking the security of road wheels.

9.4.4

Load lifting

9.4.4.1 Where vehicles are fitted with one or more load lifting points, the maintenance plan shall detail the examination and testing in accordance with the requirements of LOLER. 9.4.4.2 Where vehicles are fitted with hydraulic burst hose protection devices that are capable of

test the maintenance plan shall detail the testing required.

9.4.5

MEWPs

9.4.5.1 The examination of all load bearing structures and components shall be detailed, with the method of testing as required.

9.4.5.2 The maintenance plan shall detail the examination and testing in accordance with the requirements of LOLER.

9.4.6

RCI

9.4.6.1 Where fitted with a RCI the maintenance instructions shall detail the requirements for frequency of checking for function and accuracy. There shall also be a procedure to be followed post any repair to the RCI or associated components.

9.4.7

Towing equipment

9.4.7.1 The maintenance plan shall include all appropriate maintenance requirements for towing couplings and tow bars, both general and recovery types.

9.4.8

Data logger

9.4.8.1 Where fitted with a data logger, the maintenance instructions shall detail the requirements for down loading at regular intervals.

9.4.8.2 The manufacturer shall state in the maintenance plan the frequency required for testing the accuracy of the data logger.

9.4.9

Hydraulic system

9.4.9.1 Where a vehicle has a hydraulic supply the maintenance plan shall detail the hydraulic pump or system pressure and flow rates. The maintenance plan shall specify the periodicity of checks that shall be undertaken.

9.5

Document review

9.5.1 The maintenance plan shall state the periodicity of review. The plan shall include the following instructions:

a) A process for it to be regularly reviewed for potential to improve its effectiveness. b) A process for a record to be kept of decisions taken at each review.

c) A process for the maintenance plan to also be reviewed in the light of the following: i) In process reviews of maintenance activities.

ii) Performance of the vehicles and components covered by the plan including relevant national incident reports.

iii) Changes in the pattern of use and operating environment. iv) Manufacturer's advice.

v) Network Rail directives.

vi) As part of the seven-year review of the vehicle.

A key element in the development of a successful maintenance plan is a commitment to review regularly both the frequency and content of each job description. A nominated competent engineer identified by the owner should review the maintenance plan, as a minimum, every 12 months and the records retained for audit purposes.

Each component failure should be assessed to establish if there is a failure of maintenance that either caused or contributed to the failure. The maintenance plan should then be amended to reflect the lessons learnt. Regular reviews of the performance of the vehicle, reviews of maintenance activities, changes of use or frequency of use of the vehicle, and external information could all lead to changes in the plan.

Each change of the plan should be authorised by a nominated competent engineer and where reasonably practical the change should be agreed by the OEM. The amended plan needs to be re-certificated. It is

recommended that the plan is kept as a live document, with each change authorised by the competent engineer, who should decide if the amendment is serious (and requires re-certification immediately) or whether several changes can be bundled together and re-certificated at an annual review. The users of the maintenance plan should be encouraged to contribute to the review process.