AC EMU maintenance Schedule.ppsx INDIAN RAILWAYS

ac dc emu

1. MAINTENANCE SCHEDULE
OF
EMU

2. Objectives of maintenance
1. To ensure availability of Asset
2. To improve reliability of Asset
3. To reduce maintenance cost
4. To ensure safety of passengers and
maintenance man

3. 1.Preventive maintenance
2.Breakdown maintenance
3.Condition monitoring
maintenance
TYPE OF MAINTENANCE

4. 1. Preventive Maintenance
•Preventive Maintenance is maintenance in
which some faults due wear and tear are
accepted as avoidable through regular
checks, premature overhauling or
replacement of parts etc.

5. 2. Breakdown Maintenance
•Breakdown Maintenance or unscheduled
Repairs is defined as attention to equipment
for its inability to perform and not finding
place in the part in preventive maintenance

6. 3. Condition monitoring
Maintenance
1.This maintenance is derived based on
condition monitoring to achieve a high
level of reliability.
2.This maintenance has the distinct
advantage over preventive maintenance
which permits the equipment to live its full
life.

7. 3.This maintenance shall help in deciding the
intervals between two overhauling
schedules.
4.It reduces maintenance cost
5.It improves reliability by identifying
defects vulnerable to breakdown.
3. Condition monitoring
Maintenance

8. SN Type of schedule Periodicity
1 Daily Inspection everyday
2 Trip Inspection (TI)10 Days
3 IA 45 days
4 IC 180 days
5 POH 18 Months
6 Ultrasonic test 6 months
7 Washing 10 Days
MAINTENANCE SCHEDULE OF
EMU

9. TI
1. Check the condition of metallised carbon strips
for their breakage, chipping & flashing.
2. Cleaning of roof insulator
3. Check & ensure panto raising & lowering
operation from BL switch and within the requisite
time and steps for both operation.
Pantograph

10. IA
1.Ensure lubrication of all joints
2.Measurement of thickness of strip
3.Check & ensure any sign of crack
development and effectiveness of plunger box
4.Check & ensure intactness of all fasteners
and its tightness checking.
Pantograph

11. IC
1. Ensure static balance testing of pantograph by
7kg weight
2. Ensure greasing of servomotor
3. Ensure greasing of throttle valve & changing of
rubber kit.
4. Greasing of bearings
Pantograph

12. TI
1. TFP oil level
2. Oil leakage
IA
1. Condition of Silica gel and replacement if
required
2. Cleaning of transformer
3. Visual, but closely checking of power cables
for its tightness etc.
Transformer

13. IC
1. DGA test of Transformer oil
2. IR measurement of transformer
3. Tightness checking of power cable &
terminal boards and its Cleaning
4. Breakdown voltage test of oil.
POH1. PRV calibration
2. Oil filtration
Transformer

14. TI1. Check for any damage to TM cables along with
proper securing, rubbing of cable with magnet
frames to be arrested.
IA
1. TM blowing
2. Cleaning TM’s suction air filters by air blowing.
3. Ensure securing of air bellows with duct and
condition of duct for any cracks.
4. Intactness of earthing brush and its functioning.
5.Ensuring intactness of all connections and
securing inspection covers.
Traction Motor

15. IA
6. Ensuring the intactness of nose plates fitted in
magnet frame.
7. Checking of condition of commutator along
with carbon brush if required
8. Check for any flash over sign and
measurement of gap between brush box and
commutator.
9. Checking & ensuring of intactness of end
shield bolts, fan chamber, end plates, duct & duct
bolts
Traction Motor

16. IC
1. Measurement of gap between TM nose and
sandwitch plate by filler gauge.
2.Securing of junction box & healthiness of
incoming and out going cables
3.Check the condition of spring washers & ensure
replacement for gear case mounting bolts.
POHMeasurement of polarization index of armature
and stator.
Traction Motor

17. TI1.Checking up of oil level & topping up, if
required
2.Operational checking of compressor by way
of observing running sound, feel test for
generation of heat during run, cut in & cut out
pressure, availability of back pressure, frame
intactness / crackness
3.Cleaning of main CP suction filter (TI / IA TI if
it is in passenger compartment, IA if it is in HT
compartment)
IA1.Ensuring intactness of HP & LP safety valves.
COMPRESSOR

18. IC1.Operation checking of effectiveness of non-
return valve.
2.Replacement of oil filter along with complete
oil Changing
3.Valve cleaning
COMPRESSOR

19. IA
1.Air blowing of cubicle
2.Visual checking for any abnormal sign or loose
connection
3.Healthiness of supervisory circuit by fault
simulation
IC
1.Visual checking of diode and connections along
with continuity & checking of fuses
2.Checking of capacitors DC & AC both side
3.Tightness checking of power and LT Cables
RECTIFIER

20. IA
1.Ensure proper closing & opening of VCB through BL
switch.
2.Check & ensure proper crushing of contacts of
auxiliary switch. Check for any sign of overheating
or melting in auxiliary contacts
IC
1.Check the condition of silica gel & it should be
reactivated in case its colour fades.
2.Check the condition of air filter and ensure
lubrication of relay valve by Molygraph 44
3.Check and ensure correct setting of pressure switch
and pressure regulator
4.Ensure tightness checking of terminal board
connections. IC
Vacuum circuit breaker

21. TI1.Ensure effective functioning of horn, wiper, guard’s
emergency valve & emergency application valve
2.Ensure quality sound from horn.
3.Ensure effective securing of horn paddle and its
angle from floor to avoid any inconvenience to
running staff.
IC4.Ensure overhauling of emergency application valve
and its effective working. IC
Driving cab equipments

22. TI1.Free operation of MP at different position
2.Operation and checking of Dead man’s valve
IA1.Operational checking and cleaning of interlocks
2.Tightness of locking screw and cover latch
3.Operational checking of contactor by manual
operation
IC1.Lubrication of gear and bearing
MASTER CONTROLLER

23. TI
1.Ensuring effective working of brake controller in
different position after fitment of reducing valve
& all electrical connections checking.
2.Operational checking of brake controller &
ensuring brake application & release of each
coach
3.Ensuring effectiveness of self lapping of EP &
auto portion
4.Measurement of motor coach brake cylinder
pressure & corrective action if required
BRAKE CONTROLLER

24. IA 1.Overhauling of reducing valve & changing of rubber
parts. Ensure effective operation of brake controller
after checking in test bench. After 90 days (Alternate
IA)*
2.Checking & overhauling of equalizing discharge valve
and hand operated isolating valve and replacement of
rubber parts
3.Checking & ensuring the tightness of electrical
connections
IC 1.Cleaning & checking the brake controller finger
contacts of drum controller and mobile contacts
POH 1.Overhauling of Brake controller POH
BRAKE CONTROLLER

25. POH
1.Ensure calibration of relay CLR OL & OVR at
their predefined value. POH
2.Ensure calibration of OLP & Thermostat relay
at their predefined value. POH
RELAY CALIBRATION

26. IA
1.Effectiveness of knurling spring by pressing
bottom contact
2.Interlock arms operation and condition checking
3.Operational checking of contactor by manual
operation
4.Condition of fixed, moving contact and
examination of pit marking ,flashing if any
EP AND MOTOR CONTACTOR

27. IA5.Closing and opening of aux interlocks and
interlock crush
6.Functioning of return spring at zero pressure
IC1.Blowing & cleaning of pneumatic pipelines,
strainers & filters
2.Operation and spring tension checking of
moving contact
EP AND MOTOR CONTACTOR

28. TI
1.Distil water checking and topping up, if
required
2.Check for any sign of sulphation and its
removal, if defective.
IA
1.Condition of battery tray and repair, if required
2.Availability and continuity of battery fuse.
3.Ensuring perfect connection and securing of
cable terminal
4.Checking of specific gravity of each cell
5.•Cleaning of vent holes of vent plug
BATTERY

29. IA6.Ensure compact placement of battery cells to avoid
relative movement during run
7.Application of petroleum jelly and tightness of
terminal connection
IC1.Measurement of each cell voltage
2.Cell tap holders cleaning
BATTERY

30. IA
1.Air blowing of RF motor & filter
2.Checking and ensuring foundation tightness
3.Checking the condition of MCP and commutator
for any flashover or any defect.
4.Checking the condition of carbon brush and
changing if required.
IC
1.Air blowing of MCP motors & checking of
commutator
2.Checking for any abnormal sound on run,
observance of flashing and changing of carbon
brush if required.
AUXILIARY MOTORS

31. IC
3.Current measurement of aux. motors.
4.Measurement of capacitor value of AC motors
and replacement if found defective or low value
5.Checking of motor connection tightness at
terminals
6.Measurement of insulation, resistance of
auxiliary motors
AUXILIARY MOTORS

32. TI1.Checking of dull sound, hollow tyres, intactness
of keys & glut-ring along with skid marks, cracks
flow of metal at surface
2.Feeling of temperature of axle box housing &
condition of axle box covers, bolts etc.
IA1.Checking of thermals cracks by magnifying
glass and hollowness.
2.Measurement of wheel gauge.
WHEEL

33. IA1.Ultrasonic testing of axle IC
POH1.Ultrasonic of hanger pin POH
ULTRASONIC TESTING OF
AXLE, HANGER PIN

34. TI1.Ensuring working & application of parking
brake. TI
IA1.Ensuring intactness of fixation arrangement
of parking brake IA
PARKING BRAKE

35. TI1.Ensuring thorough draining of main reservoir,
after cooler, inter-cooler and supplementary
reservoir of trailer coaches
IA
2.Check & test healthiness of MR & BP flexible
hoses. Observe any sign of air leakage and
looseness of end fittings.
3.Ensure intactness of bogie’s pipeline clamping
and any sign of air leakage especially from “T”
joints & other unions.
4.Check and ensure proper securing of brake
cylinders and intactness of all the fasteners.
5.Ensure cleaning of MR line dirt collector.
Under frame

36. TI1.Operational checking of each EP Unit.
IA
1.Connection tightness.
2.For Escort type EP unit greasing of application
& holding magnet valve
IC
1.Overhauling and change of rubber parts of EP
unit
2.Overhauling of stabling valve & limiting valve &
replacement of rubber parts in kit.
3.After overhauling and assembly of EP unit and
accelerated testing on test bench to be done.
EP Unit

37. MAJOR ACTIVITIES IN DAILY INSPECTION
SNEquipment Activity
1.Brake
Controller
Check the operation from both the
driving cab
2.Brake TestCarry out Brake test
3.Guard
Emergency
Handle
Check for smooth operation
4.Parking
Brakes
Check the functioning of Parking
Brake Ensure parking brake push
button indication glows

38. SNEquipment Activity
5.Pneumatic
System
Check for proper position of drain
cocks.
Check for any leakage
6.Air Spring Check position of all cocks
Check the leveling valve for any
leakage
MAJOR ACTIVITIES IN DAILY INSPECTION

39. SNEquipment Activity
7.Brake
Rigging
Check for intactness palm pull rods,
safety chains, split pins, cotter, hanger
pins, safety brackets, Provide if missing.
Check for proper gap between brake
block and the wheels in release condition.
8Brake blocksReplace the missing brake blocks/worn
out brake blocks
9.Buffer &
Couplers
Proper securing of Schaku coupler.
availability & intactness of screw coupler
(In D/Cabs)
MAJOR ACTIVITIES IN DAILY INSPECTION

40. SNEquipment Activity
10.Axle BoxesFeel for hot axle
Ensure that the covers are intact and
there is no grease leakage.
11.Wheels Check for wheel defects like Flat, chip
tyre, Sharp & thin etc.
12.Line
Report/Unit
Defect
Report
Attend the defects reported
MAJOR ACTIVITIES IN DAILY INSPECTION