VICTORIAN METROPOLITAN AND REGIONAL RAILWAY ROAD RAIL ... · VICTORIAN METROPOLITAN AND REGIONAL...

VICTORIAN METROPOLITAN AND REGIONAL RAILWAY ROAD RAIL VEHICLE ACCEPTANCE CHECKLIST

MTMF 060800-09 Version: 1 Effective from: 12th December 2016 L4-CHE-FOR-058

NIFO-2831.2.

Approving Manager: Chief Engineer Approval Date: 12/12/2016 Next Review Date: 12/12/2018 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 1 of 23

This form is to be completed by a MTM and V/Line Approved Compliance Testing Company

Vehicle Owner:

Vehicle Owners Representative:

Signature:

Signature:

Assessing Company:

Person completing checklist: (Representative to meet requirements of AS 7501:2013, Section 4, Independent Competent Person )

Signature:

Signature:

Date of Assessment:

Key: H = Hold, W = Witness

Document References: AS 7500 Series MTM Standard – Track Vehicles – MTST 060800-01 V/Line Standard – Road Rail Vehicles – NIST 2831

Vehicle Description / Functionality:

Manufacturer: Vehicle Serial/Vin No:

Year of Manufacture: State Registration No:

Metro Registration Vehicle No:

Overall Length Overall Width:

Overall Height:

Number of Axles: Vehicle Tare Mass at Rail:

GVM

Axle Spacing: Maximum Travelling Speed:

Road Speed Rail Speed in Transit Rail Speed in worksite



NIFO-2831.2.


Engineering Certificate Numbers:

Road Rail Conversion ADR & VicRoads Approval:

(for road registered vehicles)

Other (additional modifications)

RRV Registration Application for: Mandatory Pages to be Completed

Mandatory Section & Items to be Completed

TV1 A non self-propelled vehicle. Pages 1, 2 & 22 All Items in Section – 1

TV2 A self-propelled vehicle which does not reliably operate track circuits. Pages 1, 2 & 22 All Items in Section – 1, 2, 3, & 4

TV3 A self-propelled vehicle which operates track circuits. Pages 1, 2 & 22 All Items in Section – 1, 2, 3, 4, 5, & 6

Photographic evidence to be retained showing condition of the vehicle and road rail equipment at time of Inspection.

A set of photos showing the front, rear, and sides of the vehicle/equipment while in the rail mode working condition is to be attached to the Acceptance Checklist.



NIFO-2831.2.


Remarks / Records

Item No.

Activity (Incl. the necessary inspection)

Criteria Key PASS FAIL (e.g. Reports, Certificates)

1 Vehicle propulsion system

Determine vehicle propulsion System (Engine type) Diesel Petrol Other Kilowatts / Horse Power

W

The Type of Propulsion System is:

The Kilowatts / Horse Power of the vehicle/Locomotive:

1.1 Record the type of road rail system

One of: Self-propelled Rail guidance Friction drive Flexitors installed/Size

W

The type of guidance system is:

The size of flexitor installed is:

1.2 Ensure vehicle has fail-safe road rail drive and control system.

Confirm:

H

Verify compliance: Yes / No

Method of placement of vehicle on and off track

Method of placement of vehicle on and off track is by:

Minimum one braked axle (2 wheels) in contact with rail at all times during on / off tracking.

Minimum one braked axle (2 wheels) in contact with rail at all times during on / off tracking.



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1.3 Ensure vehicle does not exceed the Network Rollingstock outlines.

Vehicle to comply with rollingstock outline for transit MTM – Drawing

STD_R0009 V/Line – RISSB Reference

Vehicle 1 (Plate A) and ARTC Network Rollingstock

outlines. Clearance to Train Stops

H

Where exceedance exists, site-specific risk assessment must be performed, to confirm if vehicle is safe for use within the closed worksite limits.

Does the vehicle clear train stops Yes No

1.4 Ensure clearance to overhead wiring is maintained.

For vehicles required to transit or operate on the Melbourne Metropolitan electrified network.

H

Applicable only if travelling / working on the electrified network.

Height Limiter installed and functional Yes No

Vehicle height in transit not to exceed 4120mm above top of rail.

Transit height below 4.120m Pass Fail

Height limiter when operational does not allow any part of the boom or the accessories to exceed 3.9 m above rail.

Maintained boom below 3.9m Pass Fail



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1.5 Ensure clearance can be maintained to railway assets in site-specific locations.

Vehicles to be fitted with slew controls and gage settable to railway structures. H

Applicable to Excavators, Backhoes, and Vehicles with Cranes Installed.

Yes / No

Slew limiting control installed & operational

Does the Excavator have zero swing? (Vehicle swing limited to 1500 mm radius from rail track centre)

W

Applicable to excavators, cranes and backhoes

Yes / No

Manufactured with Zero Swing tolerance

Does vehicle have a means of securing vehicle for transit H Means of securing vehicle for transit

1.6 Ensure vehicle capable of negotiating minimum radius curve.

Minimum radius 100 m. H

Verify by calculation or by demonstration of compliance with a template that all tyres are fully in contact with the head of the rail.

1.7 Ensure wheel profile complies with MP2 or ANZR1

Wheel profile within acceptable wear limits. H Mandatory requirement.



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1.8 Confirm vehicle service brake functionality

Confirm the type & effectiveness of the vehicles service brakes;

H

Mandatory Requirement Comments/ Results

Test speed & type

Braking rate from maximum speed (metres/sec)

Braking distance from maximum speed (metres)

Confirm vehicle park holding system on gradients

Confirm the effectiveness of the vehicles park brake on gradients; Ensure parking brake holds

vehicle on a 1:30 grade. Ensure vehicle with towing

ability has parking brake to hold vehicle and rated trailing load in 1:30 grade.

Test to verify vehicle held without movement for 15 minutes.

H

Capacity to be held on 1 in 30 grade

If movement is observed, vehicle cannot be accepted for operation on site. Park brakes are to provide positive mechanical locking of the brake system. Park brakes held by hydraulic means are not acceptable. Mechanical park brakes released hydraulically are acceptable.

1.9 Confirm maintenance regime includes annual crack test (PT) of rail wheel stub axles and wheel bearing check.

Annually dye penetrant (PT) test and wheel bearing check is required and the results to be recorded & retained W

Dye Penetrant (PT) test and wheel bearing maintenance records must be up to date prior to accept vehicle for operation on rail network. Completed maintenance records to be witnessed by the Assessor and provided with checklist on request by issuing officer.



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1.10 Confirm that a Vehicle Operation Manual is stored on the vehicle

Sight the Vehicle Operation Manual W

If a Vehicle Operation Manual is not stored on vehicle, vehicle cannot be accepted for operation on site.

1.11 Confirm that Plant Hazard Assessment is stored on vehicle.

Sight PHA & confirm date and Vehicle ID matching. W

If Plant Hazard Assessment is not stored on vehicle, vehicle cannot be accepted for operation on site.

1.12 Confirm those vehicles service & maintenance records are up to date.

Vehicle service & maintenance to be performed in accordance with manufacturer’s specifications.

W

Vehicle service & maintenance records must be up to date prior to accepting vehicle for operation on rail network. Completed maintenance records to be witnessed by the Assessor and provided with checklist on request by issuing officer.

Confirm the vehicle maintenance frequency

Copy of manufactures recommended schedule to be attached to this checklist. W

State vehicle maintenance frequency: Months/Kms

Confirm that Rail Guidance Maintenance Records are up to date.

Maintenance for rail guidance system to be performed in accordance with manufacturer’s specifications.

W

Rail guidance maintenance records must be up to date prior to accepting vehicle for operation on rail network. Completed maintenance records to be witnessed by the Assessor and provided with checklist on request by issuing officer.

Confirm the Rail Guidance maintenance frequency

Copy of manufactures recommended schedule to be attached to this checklist. W

State vehicle maintenance frequency: Months/Kms

1.13 Confirm that Logbook is stored Sight Logbook. W If Logbook is not stored on vehicle, vehicle cannot be



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on vehicle and is up to date. accepted for operation on site.

1.14 Confirm procedure for leaving vehicle powered down or unattended is in place.

Leaving vehicle unattended or powered down does not present potential for plant to ‘run away’. Preferred method is to have vehicle lowered onto ground and park brake applied.

W

If procedure is inadequate, a procedure must be developed by the worksite team prior to operation on site and detailed below. Minimum requirements are (write below):

1.15 Ensure vehicle’s traction / braking system is fail-safe.

Failure of power source or system pressure does not put vehicle into ‘free wheel’ condition.

H

If the potential for free wheel condition exists, vehicle cannot be accepted for operation on site.

1.16 Confirm procedure for emergency ‘off-tracking’ is in place.

Emergency ‘off tracking’ or towing does not present potential for plant to ‘free wheel’. W

Vehicles to be fitted with jacking or lifting points as appropriate to vehicle design. If procedure is inadequate, the worksite team prior to operation on site must develop a procedure. If the potential for free wheel condition exists, vehicle cannot be accepted for operation on site.



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1.17 Confirm procedure and/or suitable equipment for emergency towing provided.

Procedure required in all cases. Towing equipment to be suitable for task & rated accordingly.

W

Mandatory requirement Yes / No

Towing procedure available in vehicle

Vehicle tow point fitted

Vehicle recovery equipment stored on vehicle

Towing capacity (kgs)

Note: You have now completed the technical requirement for a TV1 Registration. (A non self-propelled vehicle which does not reliably operate track

circuits, and which must be managed under the operating rules under conditions which exclude the operation of trains whilst the vehicle is on track)

Please proceed and complete to item 4.3 and page 22 to achieve TV2 & V Line Registration.



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2 Ensure all mechanical / electrical interlocks are functioning and operating in accordance with manufacturer’s specifications.

Interlocks in place and working per design condition.

W

If interlocks not functioning and operational within manufacturer’s specifications, vehicle cannot be accepted for operation on site

2.1 If the road rail system is ‘rail guidance’, ensure tyre condition provides sufficient traction and braking.

Tyres provide contact (i.e., correct pressure and alignment) in accordance with design condition.

W

Types must be of a roadworthy standard and inflated to manufacture’s recommended pressure. If existing tyre(s) provide insufficient contact, tyre(s) must be replaced, or road rail system adjusted and re-assessed, prior to acceptance for operation on site.

2.2 If the road rail is ‘friction drive’, ensure tyre condition provides sufficient traction and braking during operation.

All rail wheels to be fitted with independent fail-safe brakes. H

Mandatory requirement.

2.3 Confirm the road rail Hydraulics are fitted with manual override and hand pump to stow the RRV equipment for recovery

The vehicle is fitted with operational

H

Mandatory Requirement Yes / No

Manual override; Manual override Fitted and Operational

Hand pumping recovery system

Hand pumping recovery system fitted and operational

2.4 Confirm that the rail wheels when lowered for rail travel are locked in the on rail position.

Confirm that the rail wheels cannot be adjusted from the on rail stop position when engaged.

H

Mandatory Requirement

2.5 Vehicle stability Vehicles requiring stabilisers in operation not to use rail clamps. H Rail clamps are prohibited. Vehicles requiring stabilisers

are to be fitted with devices that do not contact rails.



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3 Carry out wheel & rail axle static weight measurement - attachment (if applicable) proposed for task to be installed on vehicle.

Weight not to exceed manufacturer’s rated capacity. Maximum allowable axle load is 19 tonne.

H

Axle on Rail

Manufacturer’s Rated Axle

Capacity (KG)

Actual Measured Load (KG)

Pass / Fail

Axle 1

Note: Should a vehicle exceed the load rating capacity of up to 10% the company maybe be given 6 months to modify vehicle design to comply if the assessor considers the flexitors are serviceable to carry the extra load.

Axle 2

Axle 3

Axle 4

Axle 5

Axle 6

Where vehicles axle weight is by <10% a M64 Restriction can be issued to all the vehicle to operate up to 6 months while a design and modification is carried to RRV equipment to bring it within tolerance.



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3.1 Carry out static twist test. Wheel unloading not to exceed 60% Twist (mm) / Wheelbase (mm). 1:100 over 4 metres and then 1:250 for longer vehicles. AS 7509.4 2009, clause 6.3.2.2

H

Measured Wheelbase = mm Calculated Wheel packing height (1:100 x Wheelbase) = mm

Twist test criteria must be met for all vehicle operation on open running line.

Rail Wheel

Wheel Load Level

Ground P Force (KG)

Wheel Load

Packed condition P Force

(KG)

Wheel Unloadin

g (%)

Pass / Fail

Note: Test is to be carried with tyres in a road worthy condition and at the pressure recommended by manufacturer for load carried.

WF Left

WF Right WR Left

WR Right

WR Left

WR Right

WF Left

If wheel unloading exceeds 60%, site-specific risk assessment must be performed, to confirm if vehicle is safe for use within the closed worksite limits. Risk assessment to define maximum speed.



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3.2 Carry out back-to-back gauge measurement on each Rail Wheel Set (at rail level).

Broad gauge tolerance = 1523mm to 1525mm Standard gauge tolerance = 1358mm to 1360mm

H

Axle on Rail

Actual Back to Back Measurement (mm)

Pass / Fail

Axle 1

Axle 2

Axle 3

Axle 4

If back to back tolerances exceeded, road rail system to be adjusted and re-assessed prior to acceptance for operation on site.



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3.3 Ensure sufficient braking performance appropriate to operating speed.

Speed 15 to 20 km/h - Vehicle must come to a complete stop within 20 m.

H

Test speed: km/h

Speed 40 km/h - Vehicle must come to a complete stop within 70 m.

Stopping Distance: m

Speed 60 km/h - Vehicle must come to a complete stop within 155 m.

Deceleration Rate (optional): m/s2

Note 1: test to be carried out on level tangent track in dry conditions.

Measured braking distance must comply with criteria from the vehicle maximum allowable speed on rail.

Note 2: The 60km/h test is based on deceleration of 0.9 m/s2

Stopping Distance

m

Speed km/h

Deceleration Rate -m/s2

Test 1

Test 2

Test 3

Test 4



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3.4 Ensure minimum required items of visibility & warnings are fitted and operational.

Minimum items:

H

The vehicle is fitted with operational: Pass / Fail

1. Visual indicators to show RRV equipment engagement

Visual indicators on RRV equipment engagement

If any of the Criteria is not fitted and operational, vehicle cannot be accepted for operation on the rail corridor.

2. Headlights front and rear Headlights Front & Rear

3. Windscreen Wipers fitted and functional?

Windscreen Wipers

4. Marker lights front and rear Marker Lights Front (White lights) & Rear (Rear Red Lights)

5. Work lights On track working appropriate lighting

6. Horn Horn

7. Speedometer Speedometer (type):

8. Rotating beacon Rotating Beacon

9. Broadband reversing buzzer Broadband reversing Buzzer (Day / Night)

10. Brake light Brake Lights

11. Handbrake fitted and functional

Handbrake fitted

12. Reflective Striping and Delineators

Reflective Striping and Delineators

13. Compliance plates fitted to RRV equipment.

Compliance plates fitted to RRV



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14. Electrical Danger Stickers and Decals

Electrical Danger Stickers and Decals

15. First aid Kit First aid Kit

16. Fire extinguisher (2.5KG) Fire extinguisher - Expiration Date:

17. UHF Radio - Minimum of 15 channels (Plant Only)

UHF Radio (Plant Only)

3.5 Ensure equipment provided for operation on the running line on the Victorian Rail Network. Note: Not required for TV1 & 2 vehicles operating on the Metro rail network.

Confirm the train to base radio (and/or ICE Digital Radio depending on location and transitional implementation) installed in the vehicle is serviceable and operational

H

ICE/Train-to-Base communication system This system is mandatory to be installed if requesting to run on running lines.

Confirm the Vigilance Control System fit to the vehicle is serviceable and operational

H VC System This system is mandatory to be installed if requesting to run on running lines.



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3.6 Confirm vehicle/equipment stability in operation and roll over protection (ROP) and falling objects protection (FOP) are appropriate for the tasks

Vehicle/equipment has stabilising equipment where appropriate and vehicle has ROP and FOP installed. For a vehicle to qualify as providing ROP & FOP protection a Manufactures Compliance plate must Specify: The AUS Standard, or

equivalent International standard,

or Have an engineering

certificate, (The engineering certificate must accompany the application for registration), or have a Compliance plate fitted to the vehicles.

H

Protection installed Pass / Fail

Stability Protection

Roll Over Protection

Falling Object Protection

Compliance Plate Fitted

ROP Installed to AUS / equivalent International Standard. State Standard:

ROP Installed to AUS / equivalent International Standard. State Standard:

If vehicle/equipment stability in operation at maximum reach is not proven vehicle cannot be accepted for operation on site. Where Stability protection is not fitted a specific risk assessment must be attached to this application showing clearly the allowable working limits.



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4 Confirm the following minimum requirements for any applicable Attachment(s). Ensure information is provided regarding prevention of vehicle overturning with lifting / transporting rated loads.

As a minimum sight:

W

If any of the minimum requirements below are not met, the attachment cannot be used on site.

Attachment ID or Build Plate is visible on the Attachment.

Attachment Manufacturer:

Attachment is suitable for the machine size.

Attachment ID:

Rated capacity of Attachment and/or Lift Chart for attachment.

Machine size range for Attachment: To

Inspection records in accordance with manufacturer’s specification.

Is Machine within size range (circle one) YES / NO

Attach manufacturer’s documentation.

Rated capacity of Attachment is:

Lift Chart sighted (circle one) YES / NO

Inspection records sighted (circle one) YES / NO



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4.1 Confirm all attachments associated with Vehicle/Plant are listed and in serviceable condition

Inspect the Vehicle/Plant attachments: Correctly sized for the

machine; In a serviceable condition; Registered against the

machine; Serial number is identifiable. Note: Any attachment not inspected or not listed for use by the vehicle plant cannot be used within a rail corridor

W

The attachments associated with the operation of the vehicle/plant are:

Attachment Serial No.



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4.2 Confirm the following minimum requirement for vehicles required to be used in tunnels.

Diesel engine fitted with scrubber.

or Euro 5 emission standard

applies.

W

Only applicable for activities within tunnels – MTM requirement only.

4.3 Emission Testing Determine emission level to ensure compliance to Euro 5 emission limits specified in UN regulation 83 Revision 5.

Future Levels Yet to be Confirmed

H

Sedans, passenger cars, utility and light trucks < 3.5 tonne; or Diesel Trucks > 3.5 Tonne. Should the emission Standard not be achieved the vehicle will not be allowed access to the MURL.

Note: You have now completed the technical requirement for a TV2 and V Line Registration. (A self-propelled vehicle which does not reliably operate track circuits and which must be managed under the operating rules under conditions which exclude the operation of trains whilst the vehicle is on

track)

Please proceed and complete to item 6 and page 22 to achieve TV3 Registration.



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5 Ensure equipment provided for operation on the open running line on the Victorian Regional Network.

H

The vehicle is fitted with operational: Pass / Fail

Train to base radio (and/or ICE Digital Radio depending on location and transitional implementation).

Train to base radio (and/or ICE Digital Radio)

Vigilance Control System. Vigilance Control System.

Two each red and green flags.

Two each red and green flags.

Two boxes of Audible Track Warning devices (ATW) in a suitable container.

Two boxes of Audible Track Warning devices

One multi-coloured hand lamp or torch.

One multi-coloured hand lamp or torch.



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6 Vehicle to operate Track circuits and is managed as a train

Ensure self-propelled vehicle operates track circuits and is managed as a train under the operating rules applicable to the management of metropolitan trains on the network

H

Mandatory Requirement Yes/No

Vehicle has a proven ability to operate track circuits

Managed as a train under the operating rules applicable to the management of metropolitan trains on the network

Note: You have completed the technical requirement for TV3 Registration (A self-propelled vehicle which operates track circuits and is managed as a train under the operating rules applicable to the management of metropolitan trains on the network)

Please proceed and complete page 22



NIFO-2831.2.


COMMENTS

This form is to be completed for each road rail vehicle to demonstrate that the vehicle is fit for purpose and complies with OH & S standards.

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