MAINTENANCE OPERATION WORLDWIDE PROJECTS

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MAINTENANCE STRATEGY

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Preventive scheduled maintenance to ensure fleet availability

We provide a rapid response to day-to-day issues and incorporate corrective maintenance into our interventions, adjusting and rescheduling milestones according to the requirements of each project.

BACK TO MAINTENANCE

Basic Inspection & Servicing

Baseline inspection at commissioning.
Routine servicing to ensure operational readiness and fleet availability.

30 days

SCOPE

Visual inspections
Fluid replenishment
Functional checks
Safety verification

Light maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

Inspection Maintenance Level 1

Routine inspection and servicing. Preventive inspection focused on operational safety and reliability.

7.2 months

90000 km

SCOPE

Brake inspection
Door systems check
HVAC verification
Diagnostic review

Light maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

PARTIAL DISASSEMBLY Partial

1-Year Inspection

Annual preventive maintenance. Comprehensive assessment of vehicle systems and infrastructure interfaces.

1 year

150000 km

SCOPE

Mechanical inspection
Electrical testing
Structural assessment
Performance diagnostics

Light maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

PARTIAL DISASSEMBLY Partial

Inspection Maintenance Level 2

Intermediate inspection with enhanced checks. Maintain gearbox performance and reduce mechanical wear.

14.4 months

180000 km

SCOPE

Oil replacement
Leak inspection
Gearbox condition verification

Light maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

PARTIAL DISASSEMBLY Partial

2-Year Inspection

Extended periodic inspection covering critical safety and propulsion systems.

2 years

300000 km

SCOPE

Bogie systems
Brake equipment
Electrical cabinets
Structural inspections

Light maintenance Medium maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

PARTIAL DISASSEMBLY Partial

Inspection Maintenance Level 3

Preventive maintenance of propulsion and pneumatic equipment.

2.4 years

360000 km

SCOPE

Traction motor lubrication
Compressor filter replacement
Functional testing

Medium maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

PARTIAL DISASSEMBLY Partial

Inspection Maintenance Level 4

Major scheduled inspection. Maintenance of emergency access mechanisms to ensure accessibility and compliance.

4.8 years

720000 km

SCOPE

Cleaning of mechanisms
Lubrication of guides
Functional testing
Wear inspection

Heavy maintenance Medium maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

8-Year Overhaul

Overhaul of critical pneumatic and safety-related equipment.

8 years

1200000 km

SCOPE

Vacuum indicator overhaul
Condensate separator overhaul
Safety valve overhaul
Solenoid valves overhaul
Silencer overhaul
Reservoir drain systems

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

Wheelset Overhaul

Restore wheelset condition and running performance (wheelset reprofiling. overhaul or replacement).

8 years

1200000 km

SCOPE

Wheel replacement

Axle inspection

Bearing replacement as required

NDT examinations

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

Revision

Major overhaul of traction systems: propulsion and onboard electrical systems.

9.6 years

1440000 km

SCOPE

Asynchronous traction motor overhaul
Replacement of motor elastic supports
Service battery overhaul
DC circuit breaker rubber components replacement
Fire extinguisher recertification

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

10-Year Overhaul

Comprehensive overhaul of braking. suspension and pneumatic equipment.

10 years

1500000 km

SCOPE

Safety. leveling. pressure and compensating valves
Air reservoirs and purge systems
Metalastic springs replacement
Fire detection and suppression systems
Pantograph overhaul
Parking brake panel overhaul
Air suspension control panel overhaul
Cab auxiliary panels
Direct brake control panel
Anti-skid valves
Oil-free compressor overhaul

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

12-Year Overhaul

Overhaul of power collection and auxiliary power systems.

12 years

1800000 km

SCOPE

Automatic lowering pantograph system
Semi-permanent coupler overhaul
Manual coupler overhaul
Inverter drive system overhaul
HVAC evaporator motor replacement
Battery charger overhaul

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

15-Year Overhaul

Refurbishment of accessibility and onboard comfort systems.

15 years

2250000 km

SCOPE

PRM ramp overhaul
Driver desk refurbishment
PAE rubber elements replacement
Cab convector heaters overhaul
HVAC compressor replacement
Fire-extinguishing agent tank replacement

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

Second Wheelset Overhaul

Second lifecycle overhaul of wheelsets.

16 years

2400000 km

SCOPE

Wheel reprofiling
Bearings inspection/replacement
Axle verification

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

Second Revision

Major overhaul of dynamic behaviour and auxiliary electrical systems.

19.2 years

2880000 km

SCOPE

Metalastic springs overhaul and testing
Anti-roll system overhaul
Electrical installations overhaul
Auxiliary converter inspection
Converter seals replacement
Inverter drive controls inspection
Traction rods overhaul

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

20-Year Overhaul

Mid-Life renewal of safety-critical and power collection systems.

20 years

3000000 km

SCOPE

Fire suppression tanks replacement
Pantograph replacement
Direct brake control panel overhaul
GTA electric motor overhaul

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.

DISASSEMBLY Yes

Fourth Revision

Long-term life extension overhaul to ensure continued fleet operation beyond original design life.

38.4 years

5760000 km

SCOPE

Scope to be defined based on condition assessment and modernization strategy

Heavy maintenance

For the first two years under warranty, CAF delivers close, end‑to‑end support across the entire fleet.