MAINTENANCE SCHEDULE

OF
EMU/MEMU

N.D.TURKAR/PL/IRIEEN
 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(cont..)

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/MEMU
3PH & Conventional
RB LN EL/4.6.1/3 PH dated 06.09.2019
SN Type of schedule Periodicity

1 Daily Inspection everyday

2 Trip Inspection (TI) 15+0-3 Days

3 IA (1 day 8 hrs) 60+0-5 days

IC (2 days,6 coaches per
4 240+0-10 days
day, 8+ 8 hrs )
24+0-1
5 POH(21 days) Months(3PH),
18 Months (Con)
6 Ultrasonic test 210+- 30 days

7 Washing 10 Days
 Pantograph
1. Check the condition of metallised carbon
strips for their breakage, chipping &
flashing.

TI 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(cont..)
1. Ensure lubrication of all joints.

2. Measurement of thickness of strip.

3. Check & ensure any sign of crack

IA
development and effectiveness of plunger
box.

4. Check & ensure intactness of all fasteners

and its tightness checking.
 Pantograph(cont..)

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.

IA 2. Cleaning of transformer.

3. Visual, but closely checking of power

cables for its tightness etc.
 Transformer(cont..)
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(cont..)
6. Ensuring the intactness of nose plates fitted in
magnet frame.

7. Checking of condition of commutator along

IA 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(cont..)
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 / crack ness

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(cont..)

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 connection.
IA 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.
 Driving cab equipment.
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 1. Ensure overhauling of emergency application

valve and its effective working.
 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(cont..)
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 their predefined value.

POH

2. Ensure calibration of OLP &

Thermostat relay at their
predefined value.
 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(cont..)
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(cont..)
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.
3. Checking the condition of MCP and
IA 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(cont..)
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.

2. Connection tightness.
IA 1. For Escort type EP unit greasing of application
& holding magnet valve.

2. Overhauling and change of rubber parts of EP

unit.
1. Overhauling of stabling valve & limiting valve &
IC replacement of rubber parts in kit.
2. 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(cont..)

Sr 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(cont..)
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(cont..)

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
THANKS