On-the-Job Training Standards 

For

Grade Crossing Safety Maintenance Personnel

March 30, 2023 
Page 2 of 14

Foreword 

The OJT tasks identified below assumes a continuous and ongoing positive conversation between 

the designated instructor / qualified person and trainee. It means enough opportunity for 

conversational feedback before, during, and after any task is undertaken. The purpose of this 

conversation is to ensure learning transfer occurs. Depending on task complexity and learner 

skill level, most adults gain mastery of new skills through practice and repetition. OJT 

standards provide the basis for measuring mastery of new skills in a fair and objective 

manner. It is understood that many of the tasks below are presented in a manner that may 

suggest non-complying conditions must be present for the trainee to demonstrate 

proficiency. That is not the case and it is for this reason that a positive conversation between 

teacher and learner is encouraged throughout the OJT process. 

Please also note that there is no obligation under 49 CFR Part 243 for employers to train safetyrelated railroad employees on skills they will never apply in connection with their duties. For 

example, if an employee will not be required to perform duties in passenger service, no training 

on those tasks is required. 
Page 3 of 14

On-the-Job Training Roles and Responsibilities – Example Template

1. The designated instructor serves as the overall coordinator of the specific OJT program 

and is primarily responsible for: 

• Acting as the principal point of contact for the process, and ensuring the process is 

properly implemented. 

• Ensuring that all trainees and qualified persons involved in the OJT process have 

received hard copies of the OJT program or electronic copies of the checklist.

• Providing guidance to both the trainee and qualified person in the process once they have 

received the OJT program.

• Ensuring that trainees have access to all the supporting publications listed in this OJT 

program. 

• Ensuring the trainee has successfully completed all safety-related tasks to become a 

qualified member of an occupational category or subcategory. 

2. The qualified person (sometimes referred to as a peer trainer) may serve as the 

mentor/coach for trainees. The qualified person must be qualified and has a duty to 

communicate with the trainees to ensure OJT is properly administered throughout the 

process. The qualified person will also provide daily briefings at the beginning and end of 

each day regarding the specific tasks focused on during that day. The trainee may perform 

OJT under the direct onsite observation of any qualified person, provided the qualified 

person has been advised of the circumstances and is capable of intervening if an unsafe act or 

noncompliance with Federal railroad safety laws, regulations, or orders is observed. 

However, the trainee must demonstrate OJT proficiency to the satisfaction of the 

designated instructor to become a qualified member of an occupational category or 

subcategory. A designated instructor and qualified person can be the same person. 

3. The trainee (new hire) has the responsibility to pay close attention to the qualified person 

providing OJT, and to take advantage of the knowledge and experience he or she has to offer. 

Tracking progress of the OJT is essential and is the trainee’s responsibility. Trainees should 

be aware of, and abide by, the following: 

• The designated instructor and/or qualified person will provide practical information and 

advice on the requirements and responsibilities of assigned duties. 

• Trainees are responsible for completing any narrative and self-study assignments outside 

the scope of this OJT program. Additional assignments are an integral part of the training 

experience and must be completed before being deemed qualified by the employer. 

• To gain the maximum benefit from the OJT experience, trainees should: 

o Remain alert and involved in the training activities. 
Page 4 of 14

o Ask questions and learn from feedback. 

o Take notes and apply previous lessons. 

o Complete all required assignments. 

o Become familiar with and comply with FRA regulations, railroad safety rules, and 

other procedures mandated as a condition of employment by the employer. 

o Develop and maintain a learning attitude. 

• The OJT experience is designed to be much more than following a qualified person 

around and watching what he or she does. Trainees must take an active role in the OJT 

and thoroughly engage in the various job tasks outlined in this OJT program. 

 

• Expect the qualified person to say, “Here, you give it a try.” Remember, while 

progressing through the OJT program, trainees can learn skills, to develop knowledge, 

and to adopt work habits and routines that will last throughout a railroad career. 

• Tracking and documenting OJT progress is an essential process step. 

Guidelines for On-the-Job Training Program Coordination and Administration 

In most cases, the first week or so of employment will involve administrative details and an 

overall orientation. Although it is understood that a trainee’s duties may overlap with other 

organizational requirements, each day of OJT should focus on one of the major duties of the OJT 

program to the extent possible. Once the tasks have been selected, there should be both an initial 

briefing on the tasks to be completed at the beginning and end of each day. 

• The purpose of the debriefing is to go through the day’s activities, and to focus on each of 

the tasks associated with the task selected. 

• There is no required sequential order for completing the OJT associated with any task, 

and no attempt is made to prioritize any tasks. Although OJT should be focused on a 

task, it is anticipated that the task standards will be accomplished based on available 

training opportunities. 

Important Note: Although OJT is a critical aspect of 49 CFR Part 243, FRA will consider, on a 

case by case basis, alternate approaches to OJT in lieu of the traditional approach (see 49 CFR § 

243.5- On-the-job training). For example, some employers or training organizations may have 

access to state of the art indoor/outdoor training facilities that permit students to practice tasks 

that require neuromuscular coordination to learn in a controlled environment with minimal or no 

risk of personal injury. Other approaches may include; classroom practical exercises, role play, 

lab simulation, virtual reality (VR), and other emerging technologies. While FRA does 

encourage alternate approaches to OJT to lessen the risk of personal injury exposure to students, 

enough detail must be included in the submission and satisfy the regulatory requirements of 49 

CFR § 243.101(d) (1-3).
Page 5 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-1: Ground tests

(234.249) Test for and detect 

circuit grounds. 

Given a VOM meter, and the applicable 

circuit plan, the employee must be able to 

demonstrate the ability to: 

Reference: 49 CFR §§ 234.213 and 

234.103. 

Determine which circuits affect the proper function of the 

warning system. 

Detect any circuit ground or combination of grounds that 

permit a current flow of 75 percent or more of the release 

value of any relay or electromagnet device in the circuit. 

Troubleshoot, locate, and eliminate the ground or grounds. 

Alternatively, if the ground(s) cannot be eliminated or 

reduced to less than 75 percent of the release value of any 

relay or electromagnet device in the circuit, take appropriate 

action(s) to warn highway traffic and railroad employees. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.

Task 1-2: Standby power

(234.251) Test standby power 

system for proper function and 

capacity. 

Given a highway-rail grade crossing 

warning system circuit plan, an accurate 

timing device, and a VOM , hydrometer, 

or a peak hold meter the employee must 

be able to demonstrate the ability to: 

Reference: 49 CFR § 234.215.

Determine if the standby power system provides sufficient 

capacity to operate the warning system for the time that is 

specified on the location circuit plans. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 6 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-3: Flashing light units 

and lamp voltage (234.253) 

Test and inspect flashing light 

units and lamp voltage. 

Given a VOM, an accurate timing device, 

and appropriate hand tools, the employee 

must be able to demonstrate the ability to:

This standard must be successfully 

completed on at least three warning 

systems. If three systems are not 

available, the task must be completed 

three times on the same warning system 

on three different inspections. 

Reference: 49 CFR §§ 234.217 and 

234.221. 

Determine if each flashing light unit is positioned and 

aligned properly and visible to highway users approaching 

the crossing. 

Determine that each flashing light unit is sealed properly to 

prevent dust and moisture from entering the unit. 

Determine that all light units flash alternately at a rate 

between 35 and 65 flashes per minute. 

Determine that the voltage to each lamp is maintained at not 

less than 85 percent of the rated voltage for each 

incandescent lamp or LED. 

Clean lenses as needed.

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 7 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-4: Gate arm and gate 

mechanism (234.255)

Test each gate arm and gate 

mechanism.

Given an accurate watch or other timing 

device and necessary hand tools, the 

employee must be able to demonstrate the 

ability to: 

This standard must be successfully 

completed on at least three warning 

systems. If three systems are not 

available, the task must be completed 

three times on the same warning system 

on three different inspections. 

Reference: 49 CFR § 234.223. 

Determine that each gate arm extends across each lane of 

approaching highway traffic. 

Ensure that the gate arm is maintained in a condition 

sufficient to be clearly seen by an approaching motorist or 

pedestrian.

Determine that the gate arm starts downward movement after 

a delay of at least 3 seconds of the activation of the warning 

system.

Ensure that the gate arm is in its full horizontal position no 

less than 5 seconds before the arrival of a normal train 

movement. 

Determine the proper function of each gate mechanism’s 

hold clear device.

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 8 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-5: Warning system 

operation (234.257)

Operationally test the highwayrail grade crossing system.

Given an accurate watch or other timing 

device and a .06 ohm shunt, the employee 

must be able to demonstrate the ability to: 

Reference: 49 CFR §§ 234.105, 234.227, 

and 234.229. 

Confirm that each direct current (DC), alternating current 

(AC), and electronic track circuit within the system detects 

the presents of a .06 ohm shunt across the rails. 

Determine if sand, rust, dirt, grease, or other foreign matter is 

preventing effective train detection and take appropriate 

action to ensure the safety of motorist and pedestrians. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.

Task 1-6: Warning time

(234.259) Operationally confirm 

the warning time of the highwayrail grade crossing system. 

Given a watch or other accurate timing 

device, the employee must be able to 

demonstrate the ability to:

Reference: 49 CFR § 234.225. 

Determine that the warning system activates no less than 20 

seconds before the crossing is occupied by rail traffic. 

This can be accomplished by observation, calculation, or 

shunt simulation. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 9 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-7: Highway traffic 

signal pre-emption (234.261) 

Operationally confirm the proper 

operation of any highway traffic 

signal pre-emption 

interconnections. 

Given the appropriate circuit plans, the 

employee must be able to demonstrate the 

ability to:

Determine that the appropriate output is being provided to 

the highway traffic signal systems. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 10 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-8: Relays (234.263)

Test relays for proper operation. 

Given the appropriate relay test device 

and the appropriate manufacturer’s design 

specification and condemning limits, the 

employee must be able to demonstrate the 

ability to:

Note: This test is required:

Every 4 years for DC relays,

Every 2 years for AC relays, and

Every year for AC centrifugal relays.

Maintaining proficiency at this task may 

be problematic. Hence, retraining may be 

required before repeating this task.

Reference: 49 CFR § 234.247. 

Test at least 6 DC relays to ensure that they are operating 

within the manufacturer’s design parameters (if applicable). 

Test at least 6 AC vane-type relays to ensure that they are 

operating within the manufacturer’s design parameters (if 

applicable). 

Test at least 6 AC centrifugal relays to ensure that they are 

operating within the manufacturer’s design parameters (if 

applicable). 

If a relay fails to function in accordance with the 

manufacturer’s design parameters, remove the device from 

service.

The employee should observe the relay for improperly 

installed or burnt ribbons and contacts, moisture, or foreign 

materials within the relay.

The employee must complete this task with 100-percent 

accuracy.
Page 11 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-9: Timing relays and 

timing devices (234.265) 

Test timing relays and timing 

devices.

Given a watch or other accurate timing 

device, the employee must be able to 

demonstrate the ability to:

This standard must be successfully 

completed on at least three warning 

systems. If three systems are not 

available, the task must be completed 

three times on the same warning system 

on three different inspections. 

Reference: 49 CFR § 234.247. 

Determine that timing relays and timing devices are 

maintained such that the timed intervals are no less than 90 

percent and not more than 110 percent of the value as 

indicated on the circuit plans. 

If the timing relay or timing device fails to function as 

intended, make the necessary adjustment, repair, 

replacement, or other action to ensure the safety of motorists 

and pedestrians.

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 12 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-10: Insulation 

resistance tests, wires in 

trunking and cables (234.267)

Test insulation resistance of 

wires in trunking and cables. 

Given a megohmmeter or other highvoltage resistance-checking device, the 

employee must be able to demonstrate the 

ability to:

Note: This test is required every 10 

years. Maintaining proficiency at this 

task may be problematic. Hence, 

retraining may be required before 

repeating this task. 

Determine if wires, cables, and insulation are dry.

Determine the insulation resistance value of at least 10 

conductors, between each other and between each conductor 

and the ground. 

Take action to repair or replace any wire or cable with 

resistance between any wires or between any wires and the 

ground is less than 500,000 ohms. 

Immediately remove from service any wire or cable with 

insulation resistance between wires or between any wire and 

the ground is less than 200,000 ohms. 

If the trunking or cable fails to function as required above, 

make the necessary repair or replacement, or take action as 

required by 49 CFR § 234.247. 

This task must be successfully completed on at least two (2) 

trunkings or two (2) multiconductor cables. The employee 

must complete this task with 100-percent accuracy.
Page 13 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-11: Cut-out circuits

(234.269)

Operationally test each cut-out 

circuit.

Given a highway-rail grade crossing 

warning system, the appropriate circuit 

plan, and a switch obstruction gauge (if 

necessary) the employee must be able to:

This standard must be successfully 

completed on at least three warning 

systems. If three systems are not 

available, the task must be completed 

three times on the same warning system 

on three different inspections. 

Reference: 49 CFR § 234.237. 

Determine that each cut-out circuit is functioning as 

intended. If the cut-out circuit is used to detect a reversed 

switch, it must only cut out the warning system when the 

switch point is within one-half inch of the full reverse 

position. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.
Page 14 of 14

Task 1: Apply 49 CFR Part 234, Subpart D, Maintenance, Inspection, and Testing 

Performance

Tasks

Conditions

Tools, Equipment, Documents, Practice

Standards

Time, Completeness, or Accuracy

Task 1-12 Insulted rail joints, 

bond wires, and track 

connections (234.271) 

Ensure the physical integrity and 

functionality of insulated rail 

joints, bond connections, and 

track connections. 

Given a highway-rail grade crossing 

warning system installation and the 

appropriate circuit plans, the employee 

must be able to: 

This standard must be successfully 

completed on at least three warning 

systems. If three systems are not 

available, the task must be completed 

three times on the same warning system 

on three different inspections. 

Reference: 49 CFR §§§ 234.231, 234.233, 

and 234.235. 

Inspect the highway-rail grade crossing warning to ensure 

that all fouling wires consist of two discrete conductors and 

that each conductor is of sufficient conductivity to ensure 

proper operation of the warning system when the train 

detection circuit is shunted. 

Inspect the highway-rail grade crossing warning to ensure 

that each non-insulated rail joint in the train detection circuit 

is bonded and maintained in such condition as to ensure 

conductivity. 

Inspect and/or test all insulated joints in the warning system 

to ensure that no current is flowing between rails separated 

by the insulated joint sufficient to interfere with the proper 

function of the warning system. 

The employee must complete this task and the results 

properly recorded no less than three (3) times with 100 

percent accuracy.