MAINTENANCE SCHEDULE
OF
EMU
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
TYPE OF MAINTENANCE
1. Preventive maintenance
2. Breakdown maintenance
3. Condition monitoring
maintenance
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.
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
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.
3. Condition monitoring
Maintenance
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.
MAINTENANCE SCHEDULE OF
EMU
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
Pantograph
1. Check the condition of metallised carbon strips
for their breakage, chipping & flashing.
2. Cleaning of roof insulator
TI 3. Check & ensure panto raising & lowering
operation from BL switch and within the requisite
time and steps for both operation.
Pantograph
1. Ensure lubrication of all joints
2. Measurement of thickness of strip
IA 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
1. Ensure static balance testing of pantograph by
7kg weight
2. Ensure greasing of servomotor
IC 3. Ensure greasing of throttle valve & changing of
rubber kit.
4. Greasing of bearings
Transformer
1. TFP oil level
TI 2. Oil leakage
1. Condition of Silica gel and replacement if
required
2. Cleaning of transformer
IA
3. Visual, but closely checking of power cables
for its tightness etc.
Transformer
1. DGA test of Transformer oil
2. IR measurement of transformer
IC 3. Tightness checking of power cable &
terminal boards and its Cleaning
4. Breakdown voltage test of oil.
POH 1. PRV calibration
2. Oil filtration
Traction Motor
TI 1. Check for any damage to TM cables along with
proper securing, rubbing of cable with magnet
frames to be arrested.
1. TM blowing
2. Cleaning TM’s suction air filters by air blowing.
3. Ensure securing of air bellows with duct and
IA 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
6. Ensuring the intactness of nose plates fitted in
magnet frame.
7. Checking of condition of commutator along
with carbon brush if required
IA 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
1. Measurement of gap between TM nose and
sandwitch plate by filler gauge.
2.Securing of junction box & healthiness of
IC incoming and out going cables
3.Check the condition of spring washers & ensure
replacement for gear case mounting bolts.
POH Measurement of polarization index of armature
and stator.
COMPRESSOR
TI 1. 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)
IA 1. Ensuring intactness of HP & LP safety valves.
COMPRESSOR
IC 1. Operation checking of effectiveness of non-
return valve.
2. Replacement of oil filter along with complete
oil Changing
3. Valve cleaning
RECTIFIER
1. Air blowing of cubicle
2. Visual checking for any abnormal sign or loose
IA connection
3. Healthiness of supervisory circuit by fault
simulation
1. Visual checking of diode and connections along
with continuity & checking of fuses
IC 2. Checking of capacitors DC & AC both side
3. Tightness checking of power and LT Cables
Vacuum circuit breaker
1. Ensure proper closing & opening of VCB through BL
switch.
IA 2. Check & ensure proper crushing of contacts of
auxiliary switch. Check for any sign of overheating
or melting in auxiliary contacts
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
IC
3. Check and ensure correct setting of pressure switch
and pressure regulator
4. Ensure tightness checking of terminal board
connections. IC
Driving cab equipments
TI 1. 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.
IC 4. Ensure overhauling of emergency application valve
and its effective working. IC
MASTER CONTROLLER
TI 1. Free operation of MP at different position
2. Operation and checking of Dead man’s valve
IA 1. Operational checking and cleaning of interlocks
2. Tightness of locking screw and cover latch
3. Operational checking of contactor by manual
operation
IC 1. Lubrication of gear and bearing
BRAKE CONTROLLER
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
TI
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
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
RELAY CALIBRATION
1. Ensure calibration of relay CLR OL & OVR at
POH their predefined value. POH
2. Ensure calibration of OLP & Thermostat relay
at their predefined value. POH
EP AND MOTOR CONTACTOR
1. Effectiveness of knurling spring by pressing
bottom contact
2. Interlock arms operation and condition checking
IA 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
IA 5. Closing and opening of aux interlocks and
interlock crush
6. Functioning of return spring at zero pressure
IC 1. Blowing & cleaning of pneumatic pipelines,
strainers & filters
2. Operation and spring tension checking of
moving contact
BATTERY
1. Distil water checking and topping up, if
required
TI
2. Check for any sign of sulphation and its
removal, if defective.
1. Condition of battery tray and repair, if required
2. Availability and continuity of battery fuse.
3. Ensuring perfect connection and securing of
IA cable terminal
4. Checking of specific gravity of each cell
5. •Cleaning of vent holes of vent plug
BATTERY
IA 6. Ensure compact placement of battery cells to avoid
relative movement during run
7. Application of petroleum jelly and tightness of
terminal connection
IC 1. Measurement of each cell voltage
2. Cell tap holders cleaning
AUXILIARY MOTORS
1. Air blowing of RF motor & filter
2. Checking and ensuring foundation tightness
IA 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.
1. Air blowing of MCP motors & checking of
commutator
IC 2. Checking for any abnormal sound on run,
observance of flashing and changing of carbon
brush if required.
AUXILIARY MOTORS
3. Current measurement of aux. motors.
4. Measurement of capacitor value of AC motors
and replacement if found defective or low value
IC 5. Checking of motor connection tightness at
terminals
6. Measurement of insulation, resistance of
auxiliary motors
WHEEL
TI 1. 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.
IA 1. Checking of thermals cracks by magnifying
glass and hollowness.
2. Measurement of wheel gauge.
ULTRASONIC TESTING OF
AXLE, HANGER PIN
IA 1. Ultrasonic testing of axle IC
POH 1. Ultrasonic of hanger pin POH
PARKING BRAKE
TI 1. Ensuring working & application of parking
brake. TI
IA 1. Ensuring intactness of fixation arrangement
of parking brake IA
Under frame
TI 1. Ensuring thorough draining of main reservoir,
after cooler, inter-cooler and supplementary
reservoir of trailer coaches
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
IA 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.
EP Unit
TI 1. Operational checking of each EP Unit.
1. Connection tightness.
IA 2. For Escort type EP unit greasing of application
& holding magnet valve
1. Overhauling and change of rubber parts of EP
unit
2. Overhauling of stabling valve & limiting valve &
IC replacement of rubber parts in kit.
3. After overhauling and assembly of EP unit and
accelerated testing on test bench to be done.
MAJOR ACTIVITIES IN DAILY INSPECTION
SN Equipment Activity
1. Brake Check the operation from both the
Controller driving cab
2. Brake Test Carry out Brake test
3. Guard Check for smooth operation
Emergency
Handle
4. Parking Check the functioning of Parking
Brakes Brake Ensure parking brake push
button indication glows
MAJOR ACTIVITIES IN DAILY INSPECTION
SN Equipment Activity
5. Pneumatic Check for proper position of drain
System 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
SN Equipment Activity
7. Brake Check for intactness palm pull rods,
Rigging 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.
8 Brake blocks Replace the missing brake blocks/worn
out brake blocks
9. Buffer & Proper securing of Schaku coupler.
Couplers availability & intactness of screw coupler
(In D/Cabs)
MAJOR ACTIVITIES IN DAILY INSPECTION
SN Equipment Activity
10. Axle Boxes Feel 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 Attend the defects reported
Report/Unit
Defect
Report
