Target cohort
Wagon maintainers, supervisors or technical staff with limited wagon maintenance experience.
Course Overview
This course is intended for personnel performing wagon inspection, testing and maintenance.
A staged assessment process for review and learning is undertaken through the course.
Brake testing where included, wheel set inspection and maintenance theory and inspection are assessed for competency and knowledge during training time. Other areas are assessed with components of written, observed, and on-the-job supervisory assessments for common maintenance tasks. This can be performed as an 'apprentice' program of training
A certificate of completion will be provided outlining areas of assessment
Course duration
Nominally 5 days. It is recommended that core task assessments for larger items such as draft gear are conducted after training as on the job experience. Flexibility in regard to this can be arranged with on the job assessments made by suitable in house assessors or supervisor.
Individual modules can be undertaken or modified as required.
Costs
Course costs will be based per the booked course and number of participants after requirements are finalised and costs estimated. Nominal cost for this course is $9200 plus expenses.
Cancellations more than two weeks prior to the course will require course costs to be invoiced if they cannot be recovered.
Postponement may incur extra costs where flights or accommodation, if required, cannot be changed.
Program structure
The course program involves splitting wagon components into sections with hands on and theory components for each. This will culminate with an overall inspection following established inspection schedules.
Performance criteria/outcome
1. Wagon maintenance overview
1.1. Principles of maintenance – aims, the role of the maintainer, responsibility and liability.
1.2. Maintenance organisation and documentation hierarchy – standards, procedures, technical bulletins, information sources, wayside detectors.
1.3. Maintenance and managing risk
1.4. Maintenance practices - basic NDT inspection, Di check, Magnetic particle inspection, Ringing.
1.5. Stores system and operation – the importance of booking out.
2. Working safely
2.1. Working safely – Isolation, common hazards, injury types and back care.
3. Wagon introduction
3.1. Wagon types and main components and systems
3.2. Lettering and decal information and stamping
3.3. Normal configuration of other wagons.
3.4. Configuration of ECP coal hoppers and differences between classes
4. Bogie inspection and maintenance (TMX and body-mounted)
4.1. Introduction to rail bogies - types, components, markings, wear indicators and gauges.
4.2. Side frame inspection, wear plates and indicators, crack areas.
4.3. Bolster inspection – Cracks, wear liners, friction wedge inspection, gib inspection and wear,
4.4. Bolster springs – types, inspection, running requirements, defects and defect indicators, measurement parameters.
4.5. Side bearer - types, components, inspection, Stucki manual, defect indicators, measurement and maintenance, replacement.
4.6. Brake rigging - Types of rigging (overview) specifics for TMX inspection, maintenance and adjustment. Identification and configuration or bogies.
4.7. Body-mounted brake rigging inspection, maintenance and adjustment. Safety loops and pin requirements and restrictions.
4.8. Bogie mounted brake inspection, maintenance and adjustment
4.9. Brake blocks, identification, wear, overhanging faults and correction, changing, trim block use and restrictions on their use.
4.10. Lifted inspection, Queen or centre casting, king pin, cracks, gib clearance,
5. Wheel set inspection and maintenance – wheels, axles, package unit and axle box bearings.
5.1. Wheelset standards
5.2. Wheel set components – axles, wheels, bearings. Numbering and markings.
5.3. How wheels work and the criticality of dimensions
5.4. Wheel parts and profile and dynamics
5.5. Wheel dimensions and wear parameters
5.6. Wheel defects – types and description
5.7. Wheel measuring – gauges and use
5.8. Axle parts and running forces
5.9. Axles inspection and defect identification
5.10. Handling, storage and transport
5.11. Introduction to bearings – standards, types, components or bearings and adaptors.
5.12. Bearing defects and causes
5.13. On wagon bearing, adaptor inspection and maintenance, unusual markings and wear, grease indications, seal inspection.
5.14. Off-wagon bearing and axle box inspection, measures, rumble test, lateral play and limits.
6. Draft gear / draw gear, and coupler inspection and maintenance
6.1. Purpose, operation, types, identification, components
6.2. Draft gear inspection, measure and fault identification
6.3. Draft pocket inspection
6.4. Draft pack and draw bar inspection, fault characteristics and fault indicators. Alignment and measurement.
6.5. Automatic coupler operation, lock and locking mechanism
6.6. Coupler wear characteristics, gauging, testing, inspection, faults, and fault indications.
6.7. Wear liner inspection, fault indications and changing.
6.8. Knuckle inspection, fault indications, cracks, testing
6.9. Draft pack, yoke and draft pocket inspection. Measure and fault and wear areas and parameters.
6.10. Draw bar and draft pack inspection.
7. Body inspection and maintenance
7.1. Structural overview, force distribution
7.2. Inspection – general inspection, fault and crack prone areas and criteria, corrosion and damage.
7.3. Off bogie inspection – centre casting inspection, wear parameters and limits and crack areas.
7.4. Centre casing crack criteria for repair or replacement.
7.5. Sidewall defects and fault causes and repair actions.
7.6. Constrained Layer Damper (CLD) strips purpose, inspection and hazards.
7.7. Crack areas, identification and repair.
7.8. Stencilling and decals. Operational and safety requirements.
7.9. Highlight painting – areas and purpose
7.10. Automatic Equipment Identification (AEI) tags function and testing.
8. Hopper door inspection and maintenance (where required)
8.1. Hopper door operation and function (Kwik drop doors) (where required)
8.2. Door and shaft types, identification and compatibility (where required)
8.3. Door inspection, gauging and measurement. (where required)
9. Air Brake equipment – Taps, brake cylinder, vent valve, EL sensor valves, slack adjuster.
9.1. Inspection
9.2. Types and component details
9.3. Types, inspection, set up and pressure adjustment
9.4. Purpose, types, operation, safety
9.5. Slack adjuster Set up and adjustment
10. Air brake testing
10.1. Optional if required. (2 days extra)
11. Specialised modules as required.
A specialist module if required for particular types or items of equipment either stand alone or included in the relevant modules. These can include safely working with tools, measuring, basic non-destructive testing or partnering with an
12. Inspection assessment
Assessment of conducting an inspection. This is extra to training time and can be carried out at a future time or an in house assessment arrangement can be made.
13. Task training and assessments
A guide to on the job in house task experience and competency is provided.