EMU Maintenance and Overhaul Procedures

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Questions and Answers

Which type of inspection is carried out daily for EMUs?

Daily Inspection (correct)

Monthly Inspection

Quarterly Inspection

Half Yearly Inspection

Where should the Intermediate Overhaul (IOH) be carried out?

At an outstation

At the workshop nominated for this purpose (correct)

In the running section

In the homing shed

What should be done by the motorman after overnight stabling of EMUs?

Inspect the inter-car hose connections

Perform the Monthly Inspection

Test the air brakes

Drain off the air reservoirs (correct)

Which inspection is performed quarterly?

Quarterly Inspection Signup and view all the answers

What type of brakes require specific testing procedures according to the content?

Electro-pneumatic brakes Signup and view all the answers

In which scenario should the detailed checklist for air brakes be preserved?

For a period of six months Signup and view all the answers

Which inspection must be conducted at the homing shed for EMUs?

Trip Inspection Signup and view all the answers

What is the primary purpose of conducting a trip inspection related to brake blocks?

To renew worn-out brake blocks Signup and view all the answers

How often should brake blocks generally be checked during trip inspections?

At intervals of 5 to 8 days Signup and view all the answers

Which component is NOT directly inspected as part of the trip inspection process?

Train interior cleanliness Signup and view all the answers

What should be done before brake blocks reach condemning thickness?

Renew them Signup and view all the answers

Which of the following checks involves ensuring the effectiveness of the safety strap?

Checking the axle guide Signup and view all the answers

What is a critical check that needs to be performed on the transformers during the trip inspection?

Check transformer oil level Signup and view all the answers

Which inspection is associated with ensuring cleanliness and operational integrity of pantographs?

Inspection for flash-marks and wear Signup and view all the answers

What maintenance action is required for silica gel during trip inspections?

Replace if the color indicates saturation Signup and view all the answers

What should you do to the oil level of the auxiliary compressor during inspections?

Top up if required Signup and view all the answers

What component should be visually inspected for damages during the trip inspection?

Bogie frame Signup and view all the answers

What should be done to the 'Schaku' couplers during inspection?

Uncouple, inspect, and lubricate as prescribed Signup and view all the answers

During the half-yearly inspection, what should be renewed in the compressor?

The oil filter element assembly Signup and view all the answers

What is the purpose of checking the air gap in electromagnetic contactors?

To ensure correct contact alignment and function Signup and view all the answers

Which component should be checked for rust, corrosion, and damage?

Body panels of the coaches Signup and view all the answers

What should be done with the voltage stabilizer transformer during inspection?

Inspect for any physical damage Signup and view all the answers

What is the main purpose of using clips made out of split pins when lifting the cylinder into position?

To retain the joint ring in exact alignment Signup and view all the answers

Which sequence of actions should be taken when tightening the nuts on the joint?

Tighten opposite nuts while assembling Signup and view all the answers

What component is involved in cutting off communication between the valve body and the vacuum chamber?

Flat valve head Signup and view all the answers

What should be used for cleaning rubber fittings on the cylinder?

French chalk Signup and view all the answers

What happens if a defective diaphragm washer is present when vacuum is destroyed?

It allows air to enter above the piston Signup and view all the answers

How should the solvent be used when cleaning metal parts of the cylinder?

All traces must be removed before replacing rubber parts Signup and view all the answers

What is the maximum piston travel allowed for effective brake power?

4" (100 mm) Signup and view all the answers

What is involved in the daily inspection conducted by the Engine Examiner?

Visual inspection and temperature checks Signup and view all the answers

What is one major consequence of not removing solvent traces before replacing rubber parts?

It causes deterioration and failure in service Signup and view all the answers

What should be checked first when inspecting traction motors?

Flash-marks and broken brushes Signup and view all the answers

Which component requires cleaning with petroleum jelly after inspection?

Battery cell connections Signup and view all the answers

During the monthly inspection, what should be done if tyre wear is found to be excessive?

Reprofile the tyre Signup and view all the answers

What should be inspected for grease leakage during the monthly check?

Axle boxes Signup and view all the answers

Which item is not included in the daily inspection list?

Inspect reversible gear-box of speedometer Signup and view all the answers

What action should be taken regarding buffer inspections?

Inspect for cracks and damages Signup and view all the answers

How often should the suction strainer and centrifugal dirt collectors be inspected and cleaned?

Monthly Signup and view all the answers

Which of the following is essential to check before the rainy season?

Leakages from the roof Signup and view all the answers

What should be done regarding shock absorbers if oil leakage is detected?

Replace them immediately Signup and view all the answers

What must be checked on the hand-brake during inspections?

Effective functionality Signup and view all the answers

Which step should be taken if the brake blocks are found to be badly worn during inspection?

Renew the brake blocks. Signup and view all the answers

What specific operational check should be performed after the passenger alarm chain is tested?

Check for noticeable air leakages in the compressed air system. Signup and view all the answers

Which component's operational effectiveness is assessed by testing the brake controller at each driving position?

The brake-pipe pressure. Signup and view all the answers

During which inspection should the condition of the bolster helical springs be verified?

Night stabling inspection. Signup and view all the answers

What should be inspected visually to identify defects during the routine checks?

The pantographs. Signup and view all the answers

Which item must always be cleaned when preparing a unit for operation?

The compartments and cushions. Signup and view all the answers

What is the main purpose of checking the deadman's device in each driving cab during inspections?

To confirm the safety mechanism is operational. Signup and view all the answers

What components should be checked for wear and damage during the Intermediate Overhaul (IOH)?

'Schaku' couplers and servomotor of pantograph Signup and view all the answers

Which procedure involves testing the dielectric strength of oil in transformers?

Testing oil samples from conservator and reactor tanks Signup and view all the answers

What action is required for the pilot valve in the Master Controller during inspections?

Clean and regrease Signup and view all the answers

Which component's tension must be measured during the inspection process?

Knuckling springs of EP contactors Signup and view all the answers

What must be done to the reversing gear-box for speedometer during the IOH?

Overhaul and test on a test bench Signup and view all the answers

Which specific maintenance task is needed for EP brake valves during the IoH?

Renew all rubber components on a complete unit basis Signup and view all the answers

What is the correct maintenance procedure for the bearings in the MG set?

Check for grease leakage and lubricate Signup and view all the answers

What condition must be evaluated regarding pantograph EP valves during inspections?

Overhaul and test Signup and view all the answers

Which part should be cleaned and lubricated in the Master Controller check?

Interlocking mechanism and notching cam roller Signup and view all the answers

What does the extinguishing of the green lamp indicate in the braking system?

Total failure of EP brakes Signup and view all the answers

What happens when the pressure in the brake pipe is reduced due to various actions?

The brake cylinder is supplied with compressed air from the reservoir Signup and view all the answers

What is the maximum pressure allowed in the brake cylinders when utilizing the auxiliary reservoir?

3.5 kg/cm2 Signup and view all the answers

What role does the triple valve play while in the 'lap' position?

It maintains intermediate pressures in the brake cylinders Signup and view all the answers

Which of the following accurately describes the behavior of the orange lamp during brake application?

It fails to light up indicating partial failure of EP brakes Signup and view all the answers

What is the pressure maintained in the main reservoir by the pressure governors?

5.8 to 7.0 kg/cm2 Signup and view all the answers

Which component is responsible for maintaining the pressure to keep the automatic brakes released?

Brake pipe Signup and view all the answers

What is the role of the brake application relay in each driving cab?

Control the supply to the brake control train wires Signup and view all the answers

How many brake cylinders are typically found on a motor coach bogie?

Four Signup and view all the answers

What position on the brake controller handle is associated with the emergency braking function?

V - Emergency Signup and view all the answers

Which of the following is included among the five train wires in the braking system?

Brake application wire Signup and view all the answers

What mechanism is used for manual release of brakes in individual bogies?

Release valves Signup and view all the answers

What is the pressure maintained in each coach's brake unit?

4.57 kg/cm2 Signup and view all the answers

What feature of the brake controller ensures that it functions in only the active cab?

Isolating valve switch Signup and view all the answers

Which system warns the driver of failures related to the EP brakes?

Warning system Signup and view all the answers

What is the primary function of the self-lapping mechanism in the brake system?

To automatically control the brake cylinder pressure based on handle movement. Signup and view all the answers

Which factor directly influences the brake cylinder pressure as the controller handle is moved?

The amount of spring compression in the control cylinder. Signup and view all the answers

What occurs if the brake cylinder pressure exceeds the limit corresponding to the handle position?

The application train-wire is de-energized. Signup and view all the answers

What happens to the application wire if there is a drop in brake cylinder pressure due to leakage?

It is re-energized to restore pressure to the desired level. Signup and view all the answers

What is the maximum brake cylinder pressure that can be achieved as mentioned?

3.5 kg/cm2 Signup and view all the answers

In positions II and V, what allows the application and holding circuits to bypass the self-lapping mechanism?

Positive acting contacts that are energized. Signup and view all the answers

Which component limits the maximum pressure in the brake cylinder beyond the set value?

The limiting valve. Signup and view all the answers

What is the primary role of the 'exhaust' in the brake system?

To release pressure from the brake cylinders when needed. Signup and view all the answers

How does the handle position affect the controlling of brake pressure?

Intermediate positions allow for graduated pressure application. Signup and view all the answers

What initiates the process of applying the EP brakes?

Moving the controller handle from position I to position II. Signup and view all the answers

Study Notes

Maintenance and Overhaul Schedules of EMUs

General maintenance schedules for EMUs (electric multiple units) are applicable, with modifications as noted.
After overnight stabling, motormen must drain air reservoirs to remove accumulated water.
Daily, trip, monthly, quarterly, half-yearly inspections, and intermediate overhauls are generally performed as part of routine maintenance.
Professional overhauls, done at workshops, are designated "POH" (Periodic Overhaul).
Specific tasks differ based on railway location and EMU type.
Annexure 4.01 provides detailed work schedules.

Scheduled Inspection

Daily inspection: Primarily for running section, but can be done in a shed or outstation as needed.
Trip inspection (IT): Performed at the homing shed.
Monthly inspection (IA): Performed at the homing shed.
Quarterly inspection (IB): Performed at the homing shed.
Half-yearly inspection (IC): Performed at the homing shed.
Intermediate overhaul(IOH): Performed at the designated workshop
POH(Periodic Overhaul): Performed at the designated workshop for each railway.

EMU Fitness Certificate

EMU fitness certificates are issued based on specific types and local conditions.
Details from Annexure 4.01 should be used as guidance, not an exhaustive set of instructions.

Testing of Air Brakes

Electro-pneumatic brakes are described in Annexure 4.02.
A supervisor is responsible for testing air brakes of complete train formations after inspections or repairs.
This should be performed at both ends of the train formation.

Maintenance of Vacuum Brakes

Details for vacuum brake maintenance are provided in TXR manuals (with a summary given here)
Vacuum brake cylinders should be examined, cleaned, and necessary repairs/renewals performed annually.
Correct fitting of components is essential to avoid leaks and ensure proper functioning of vacuum brakes.
Specific checks and cleaning procedures are needed before service.
Piston travel should not exceed 4" (100mm).

Daily Inspection

The Engine Examiner must check for unusual occurrences reported by motormen.
Auxiliaries should be visually checked for proper starting and operation.
Axles should be checked by hand to ensure normal temperatures.
Components like traction bars, pendular suspension, springs, and brake rigging are checked for abnormalities.
Controls and indications must also be checked.

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Description

This quiz covers the general maintenance schedules and inspection procedures for Electric Multiple Units (EMUs). It includes daily, trip, monthly, quarterly, and half-yearly inspections as well as details on periodic overhauls and specific tasks based on location and EMU type. Test your knowledge on the procedures and regulations associated with EMU maintenance.