Maintenance Manual AC DC EMU (Siemens) PDF

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 12 MAINTENANCE SHEDULES FOR AC – DC EMU (SIEMENS) REF: SMI for uniform periodicity of maintenance schedules for EMU (AC & DC) &MEMU...

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 12 MAINTENANCE SHEDULES FOR AC – DC EMU (SIEMENS) REF: SMI for uniform periodicity of maintenance schedules for EMU (AC & DC) &MEMU coaches (ref: RDSO / PE / SMI / EMU / 0037 -2007, Rev. 0, April 2007) 1. The various maintenance schedules periodicity for AC EMU/MEMU stock as given below should also be applicable to AC – DC EMU stock plying in Mumbai area. 2. Due attention to be paid to passenger amenities items mentioned in para ‘B’ from trip inspection onwards. LEGENDS USED: TI Trip Inspection POH 18 months Inspection IA 45 Days Inspection IC 180 Days Inspection TYPE OF SCHEDULE AND PERIODICITY FOR AC, AC - DC EMU/MEMU Type of Schedule Periodicity Daily/ Night - Trip Inspection (TI) 10 Days IA 45 Days 6 Monthly (IC) 180 Days POH 18 Months 12.1 CLEANING SCHEUDLE Washing of exteriors & wet mopping of interiors shall be done during trip inspection and brooming must be done at night stabling points every day. 12.2 ITEMS FOR DAILY CHECKING AT NIGHT STABLING POINTS (Ref: RDSO / PE / SMI / EMU / 0037 -2007,Rev. 0, April 2007) 1. Visual Inspection of wheels for cracks, checking of axle boxes, its cover and bolts. 2. Check axle guide springs, air springs, bogie frame and all brake riggings. Also check schaku couplers and side buffers. 3. Check brake blocks for their position and replacements if required. 4. Drain main reservoirs. 5. Check main compressor for their oil level. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 2 CAMTECH/E/13-14/MM AC-DC EMU/1.0 6. Check gear case suspension housing bolts etc. 7. Check all compartment lights & fans. 8. Check and test horns, wiper, dead man device, guard emergency brake. 9. Check and clean head code, look out glasses. 10. Check fire extinguishers, locking of HT compartment, driving cabs. 11. Ensure all indications lamps functioning. 12. Formation testing from both the ends and brake testing. 13. Check for all hoses, air pipes. 14. Specially check headlights, taillight and flasher lights. 15. Check for battery voltage. 16. Visual check for any oil leakage from transformer, radiator and pipe lines. 17. Go through the motorman logbook and attend the defects booked during the run. 18. Record in the logbook any other abnormalities, which need attention in shed, but ensure safety and reliability. Para ‘B’ (SMI / EMU / 0037 -2007) Passenger Amenities Items Due attention to be paid to passenger amenities items mentioned below from trip inspection onwards. S. No. ITEMS 1. Broken seats and seats frame. 2. Worn out / broken chequered plates in doorways. 3. Missing glass and louver shutter including complete window frame. 4 Missing doors. 5. Worn out / tilted foot steps 6. Missing overhead handles and hand rails. 7. Breakage of FRP panel (interior panels). 8. Missing of different types of angles/ moldings. 9. Missing of seat fittings. 10. Missing of tread plate of door. 11. Missing of luggage rake. 12. Missing of notice plates and ACP handles. 13. Condition of chequered plates. 14. Proper head code working. 15. Proper working of compartment Light & Fan. Changing of defective lamp, fan fitting etc. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 3 12.3 TRIP INSPECTION SCHEDULE (10 Days) ELECTRICAL Sr. Items to be checked Remark 1.0 Driving cab i) Check E-Cabinet for any isolation of Switches & MCBs. ii) Down load fault events from both CCUs and all the TCUs and analyze for faults. 2.0 Light & Fan i) Check operation of Lights, Fans and Ventilation switches on both positions 50% &100%. ii) Check the working of all Fans and Lights in the coaches. Attend the defects noticed. iii) Check working of Signal Bell / Emergency Bell & indication LEDs. iv) Check working of Flasher, Tail & Blinker Light and ensure smooth operation of their Push Buttons. v) Check working of Head Light & Auxiliary Head Lights at both Dim/ Bright positions. vi) Check working of DC-DC Converter for Head Light on both normal and standby positions. vii) Check working of Cab Light, Emergency Cab Light, Spot Light & Cab Fans. viii) Ensure smooth operation of all push buttons & switches in the D/ Cab. 3.0 Battery i) Check & record Battery Voltage of individual unit by 100V to 110v operating "TEST BATTERY VOLTAGE" push button in motor coach shunting cab. ii) Check for intactness of Battery Box mounting Bracket and Bolts. 4.0 Transformer i) Check oil level. Check for any oil leakage. ii) Check for any hitting / damage signs. iii) Check intactness of Transformer Mounting Bolts and availability of safety slings. iv) Check the colour of silica gel. Orange -ok , Grey- Not OK 6.0 Control and Switch Gear i) Check all MCBs & Switches for normal position on the E-Cabinet in the Motor Coach. ii) Check for set condition of Motor Protection Switch (MPS) in all the end panels. iii) Ensure proper locking of panel doors of E-Cabinet in D/cab & MC, End wall panels in all the coaches. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 4 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark iv) Ensure proper position of MVB Rake U1 U2 U3 U4 segment address selector switch 9 Car 0 1 5 - in all motor coaches. 12 Car 0 1 2 5 15 Car 0 1 2 3 7.0 Roof Equipment i) Check for any signs of external hitting/ damages/ cracks on pantograph and other roof equipment. ii) Check for any OHE rubbing marks on panto pan below Red mark. iii) Check thickness of copper Wearing Strips. It should be > 3mm above condemning size. iv) Check that wearing Strips are without Sharp Edges and ensure Screws are not projecting above the wearing strips and are properly secured. v) Check that there is no Gap between the Main wearing and End wearing Strips. vi) Ensure availability of all Bolts, Nuts, Lock-Nuts, Spring Washers, Split pins etc. of various fittings. vii) Ensure intactness of middle Articulation Assembly shaft check nut. ix) Check Bow Plunger is sliding freely while pressing and split pins are available (SIL). Check Rocker assembly for free movement (Schunk). x) Check the Control Box, Rubber Bellow & Rubber/PU Pipe for any air leakage. (Schunk) Check the Servo motor, Throttle Valve, Magnet Valve for Any air leakage. (SIL) xi) Check Horizontal Damper for Oil Leakage and smooth operation (Schunk). xii) Check for free movement of servo motor piston rod and eyelet rod. (SIL) xiii) Ensure availability of all flexible shunts and check that strands are not broken. xiv) Ensure provision of steel bracket on lower articulation to prevent earthing of anti balancing tube after uncoupling. xv) Check whether rubber stopper on the base frame and MS bracket on lower articulation is provided to prevent over turning of panto in unwired section (SIL). xvi) Check & record Raising and Lowering time of antograph 6-10 Sec xvii) Ensure pantograph is raising in three steps. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 5 Sr. Items to be checked Remark xviii) Clean all the roof Insulators with Vim powder & dry cloth. xix) In case flashing marks are noticed on the insulators, clean and apply anti tracking varnish on the flashed portion. 8.0 Main Air Compressor (Mac) i) Check for any Oil or Air Leakage from Joints, Radiator, Suction/ Delivery pipes and safety valves. ii) Check for any hitting mark/damage to the radiator. iii) Check for intactness of resilient mounting. iv) Check for any abnormal sound & excess Heat during run. v) Check Cut in & Cut out pressure of compressor Cut in 7.0 Kg/cm² governors. Cut out 8.0 Kg/cm² 9.0 Auxiliary Compressor i) Check Oil Level and for any oil/ air leakage. ii) Check the Tightness of Foundation Bolts and other fittings. iii) Ensure proper function of Aux Compressor & its Cut in 5.3 Kg/cm² governor. Cut out 6.3 Kg/cm² 10.0 APC Magnet i) Check intactness of mounting bolts. ii) Check intactness and proper securing of cable conduit. 11.0 Final Testing (From Both D/Cabs) i) Keep MMI in Maintenance Mode ii) Check Healthiness of various Lamp Indication by Pushing Test Push Button. iii) Check on MMI that all coaches are set. iv) Check the Healthiness of each and every function physically which are displayed on various screens. (Top level, Unit Level, Drive/ Brake, Energy, Fault logged, V > 0 & V = 0) of MMI. v) Check for any Error Message on the screen. vi) Check ground fault in 110V DC and 110V AC circuit by multi-meter. Record voltage between (45-55 V) +ve to ground -ve to ground. vii) Check CB set/ trip on MMI. viii) Check Panto Raising/Lowering timing on MMI. 6-10 Sec ix) Check working of Fan, Light and Ventilation (both 50% and 100%) Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 6 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark x) Check Changeover on MMI for 415V AC, 110V AC, 110V DC by operating Basic Unit Isolating Switch. xi) Check operation of Head Light, Auxiliary Head Light, Flasher, Tail Light and Blinker Lights on various positions. xii) Check operation of Signal bell and Emergency bells and their indication. xiii) Check working of PA/PIS & TMS system. Intercom, Passenger address , PIS, TMS xiv) Check for Healthiness of Head-code. xv) Check functionality of Entering Neutral Section Push Button by observing feedback on SKS 12 & 13. xvi) Check operation of "Battery Supply " switch xvii) Check working of Emergency OFF Loop push Button. xviii) Observe all Sensors Feed Back Signals in "Observer" by laptop speed sensors, BC pressure. xiv) Ensure AWS working by Pressing vigilance Push button for 8 sec. xv) Check working of Dead man valve in normal and RDM mode. xvi) Measure and record the rate of air flow of ACU & TCU U1 U2 U3 U4 blowers of all four Motor coaches ACU > 5-6m/s, TCU > TCU --------- 7-9 m/s ACU --------- xvii) Check working of audio visual and cross passing. xviii) Run down the Rake in Normal and RDM mode. xix) Check AWS Speedometer and Speed Recorder and ensure no differential error occurs from both cabs. xx) Revert to "Drive Mode" on MMI after completion of testing. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 7 12.4 TRIP INSPECTION SCHEDULE (10 Days) CARRIAGE Sr. Items to be checked Remark 1.0 Driving Cabs Check proper working of Duplex, BC, Guard's and Parking i) Brake gauges. Check for availability of Short Circuit Clips, Wooden Wedge, ii) Fire Extinguisher, ACP Bamboo. 2.0 Auto Drain Valve i) Check the working of Auto Drain Valve. ii) Check for leakage from drain valve. Replace if required. 3.0 AIR DRIER i) Check Mounting Arrangement of Air Dryer for intactness. Check functioning of Air Drier by observing Humidity ii) Indicator. iii) Check for any air leakage from Duplex piston valve. iv) Check both the towers are purging. 4.0 Parking Brake i) Check for proper fitment of Parking Brake Cylinder foundation, Brake Arm, Cup Sleeve, wire rope, release handle etc. 5.0 Schaku Coupler i) Ensure the intactness of Cup-Sleeve Bolt. ii) Check the condition of Articulation Bearing Bolt and Bush. Check for any air leakage from MR & BP Pipe bracket and iii) bushing. iv) Check the condition of centering device & lift spring. Check greasing of articulation bearing bolt and condition of v) bush. 6.0 Air Suspension i) Check foundation Allen Bolts intactness. Check for any crack, dent Marks, leakages, and hitting marks ii) on air Spring Bellow. Check the Leveling Valve Assembly for any leakage or iii) damage. Check leveling valve safety plate. iv) Ensure Air Spring iso. Cocks are in open position. v) Check all the Pipes, Couplings for any leakage and attend it. vi) Check for any rubbing/damage to Flexible Pipes and attend. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 8 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark 7.0 Piping And Reservoirs i) Check for any air leakage, ensure availability of all clamps. Check Welding Joints, Split Pins, and Fixing Bolts of all the ii) air reservoirs. iii) Ensure that the Reservoirs are intact with MS straps. iv) Check for isolation of EP/AUTO/Bogie & coupling cocks Check for any Damage to Piping and Cocks. Replace v) defective / leaking cocks. 8.0 BOGIE i) Check Bogie frame, Bolster and coach under-frame for any crack / damage. ii) Check coach sole-bar and under frame for any crack/ hitting marks. iii) Check condition of liner between Bogie & Bolster. iv) Check for healthiness and foundation intactness of lateral and vertical friction dampers. v) Check Palm-pull rods for any crack/ bending. Check condition of bushes, pins and safety Chains. vi) Check availability of pins with Bulb Cotters & Split Pins. vii) Check Side Bearer for Crack or Oil Leakage. ix) Check for Side Bearer cover jam/ loose. x) Check for bolt tightness of Center Pivot or any crack. xi) Check Axle Springs for any Breakage/ Permanent set. xii) Check and ensure the intactness of Cattle guard, Buffer foundation Bolts. 9.0 BRAKE CYLINDER i) Check fixing Bolts of Brake Cylinders for any damage or slackness. ii) Check Brake Rigging parts i.e. pins, Nut Bolts, Cutters, Split Pins of Brake Block key shoe head pins for missing, worn out, slackness. iii) Check Brake Hanger Safety Brackets and Safety Stopper Plates are intact. iv) Replace worn out Brake Blocks. v) Ensure sufficient Gap between Brake Block and Wheel. >12 mm vi) Check Brake Cylinder Piston not infringing with U Bracket in brake applied condition. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 9 Sr. Items to be checked Remark 10.0 Wheel And Axle Box i) Feel temperature of Axle Box Housing for any abnormality. ii) Check Axle Box Covers for intactness of bolts and availability of Split Pins. iii) Check the Wheel for Flat, Chipping and other defects. 11.0 Furnishing Items i) Ensure healthiness of both side curtains in both D-Cabs. ii) Check M/man seat for smooth up/down and Forward/ Reverse movement operation. iii) Check Grab Handles and Center Pole for proper intactness and welding. iv) Clean Look Out Glass and ensure clear Visibility. v) Check operation (open/close/ locking) of D/cab doors. vi) Check operation (open/close/ locking) of doors in passenger area. Check for any damages to door frames. vii) Attend broken Seats & Seat Frames and torn first class seats. viii) Ensure availability of safety cover of Articulation Bearing bolt. ix) Ensure proper cleaning of D/cab and look out glasses. x) Ensure general cleaning of all coaches. 12. Testing (Put MMI In Maintenance Mode) 12.1 Switch On DCS Key And Observe On MMI. i) Check application of holding brakes in all coaches. ii) DCS key "ON" position- 0.8 Kg/cm2 iii) DCS key "OFF" position - 1.2 Kg/cm2 12.2 EP Brake Application i) Application Timing - 4-6 sec ii) Release Timing - 4-6 sec 12.3 Auto Brake Application i) Application Timing 6-10 Sec ii) Release Timing - < 20 Sec 12.4 Emergency Brake By Power Brake Controller i) Application Timing - 4-6 sec ii) Release Timing - to be confirmed rdso 4-6 sec Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 10 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark 12.5 Emergency Brake By Brake Controller i) Application Timing - 6-10 Sec ii) Release Timing - < 20 Sec Check The Following During Brake 12.6 Application And Releasing Air leakage from Brake units/ Brake Cylinder / i) No Leakage Pipeline / Reservoir / Safety Valve. ii) Ensure No EP Unit is hunting. Safety valve should be blowing during Auto Brake iii) Application only. Check for free movement of Brake Cylinder iv) Piston during application & releasing. In case of Late Releasing of brake on MMI, v) identify the particular coach by going to Unit and attend. Check working of parking brake Application vi) /Releasing Push Button. Ensure during parking Brake application PB vii) gauge showing 0.0 kg/cm2 and during releasing 5.0Kg/cm2 Verify working of Parking Brake Cylinder in all ix) the Coaches. Check working of Emergency Valve in Normal x) and RDM from both the Cabs. Check working of Guard Emergency Handle from xi) both cabs. Check working of hooter from both cabs (M/Man xii) and GD side) and ensure no leakage from Horn Foot valve. xiii) Check BP, Charging Time from Both the D/cabs. 90-120 sec ix) Measure brake pipe pressure on Duplex gauge. ICS ON Cab-1 BP Cab-1_____ BP Cab-2_____ ICS ON Cab-2 BP Cab-1_____ BP Cab-2_____ Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 11 12.5 MAINTENANCE SCHEDULE OF AC-DC (Siemens) IA (45Days) ELECTRICAL Sr. Description Remark 1.0 Pre-Testing 1.1 Keep MMI in Maintenance Mode. 1.2 Check on MMI that all coaches are set. Check the Healthiness of each and every function physically which are displayed on various screens (Top 1.3 level, Unit Level, Drive/Brake, Energy, Fault logged, V > 0 & V = 0) of MMI. 1.4 Check for any Error Message on the screen. Check ground fault in 110V DC circuit by multi-meter. 1.5 Record voltage between (45 - 55 V) '+ve to ground, -ve to ground. Check ground fault in 110V AC circuit by multi-meter. 1.6 Record voltage between ( 45 - 55 V). 1.7 Check and ensure all MCB are set on E-Cabinet. Check and ensure all rotary switches are set in their 1.8 relevant normal position in E-Cabinet. 1.9 Check CB set/trip on MMI. Check Changeover on MMI for 415V AC, 110V AC, 110V 1.10 DC by operating Basic Unit Isolating Switch. Check functionality of Entering Neutral Section Push 1.11 Button by observing feed-back on SKS 12 & 13. 1.12 Check operation of "BA Reset" switch 1.13 Check working of Emergency OFF Loop push Button. Observe BECU Speed Sensors Feed Back Signals in 1.14 "Observer" by laptop. Check working of Dead man’s valve in normal and RDM 1.15 mode. 1.16 Ensure the functions of E-Cabinet switches. Measure the rate of air flow of ACU of all four Motor > 5-6 m/s 1.17 coaches after filter cleaning. Measure the rate of air flow of TCU blowers of all four > 8-9m/s 1.18 Motor coaches after air blowing. 1.19 Check working of audio visual. Down load the events of all Four TCU & both CCU and 1.20 analyze for any fault message. 1.21 Take energy consumed readings and reset the both counters. Take energy re-generated readings and reset the both 1.22 counters. 1.23 Take distance (km) readings and reset the both counters. 1.24 Ensure correct position of check nut in Escorts make ICS. Note the brake cylinder pressures in each coach with 1.25 SIBAS monitor both normal redundant modes of BCU. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 12 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remark 2.0 Master Controller Check the operation of Dead-man, Forward/ Reverse, DCS 2.1 Key, Traction, brake and coast position. 2.2 Visually check Encoder cable for any insulation damage. Check all electrical & micro switches connections for 2.3 intactness. 2.4 Visually check the operation of all micro switches 2.5 Ensure no excessive play in T-handle. 3.0 Push buttons & Switches. Check & ensure smooth operation with their indications of all 3.1 push buttons on Driver desk. Check Healthiness of various Lamp Indications by Pushing 3.2 Test Push Button. 3.3 Check the operation of all the switches. 4.0 End wall 4.1 Check intactness of wiring connection at MCB, Relays, Contactors etc. of all D cabs. 5.0 Transformer Check colour of silica gel. It should ORANGE. Heat/replace 5.1 the silica gel if found grey. 5.2 Check for any oil leakage. 5.3 Check working of radiator blower fans & oil pump. 5.4 Check for any hitting mark or damage. 5.5 Transformer cleaning to be done. Oil level to be checked. It should be in-between low level and 5.6 300 mark. 5.7 Ensure Earthing connection intactness. 5.8 Check the foundation bolts intactness. 5.9 Ensure Radiator fins cleanliness. 6.0 Traction Motor While rake Record the temperature at DE and NDE side of traction motor 6.1 placed in bearings by temperature gun. shed 6.2 Visual inspection for any external hitting or damage. Check intactness of TM mounting bolts & MSU half shell 6.3 bolts. 6.4 Check tightness of Gear case bolts. 6.5 Check the oil level and colour of gear case oil. 6.6 Check intactness of body earthing. Check for rubbing and damage of Traction Motor cables and 6.7 their proper securing. 6.8 Visual inspection for damage to sandwich packing. 6.9 Clean suction air filters by dry compressed air. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 13 Sr. Description Remark 6.10 Check for proper fitment and tightness of bellow. 6.11 Check for any damage. Replace if required. 7.0 Motor Suspension Unit (MSU) 7.1 Check for any sign of over-heating of bearings. 7.2 Check that the housing bolts are intact. 7.3 Check for any abnormality. 8.0 Main Compressor 8.1 Clean externally compressor body & radiator. Check operation of compressor by way of observing running 8.2 sound, feel temperature by hand. Check for any oil or air leakage from joints, suction or 8.3 delivery pipes. 8.4 Ensure oil level. 8.5 Check condition of resilient mounting for intactness. 8.6 Check & ensure tightness of foundation bolts. Check vacuum indicator on silencer (suction filter) 8.7 i) Colourless - ok ii) Red Colour - Suction filter defective 8.8 Ensure proper tightness of delivery pipe. 8.9 Ensure the healthiness of mounting wire ropes. 8.10 Clean air suction filters by dry compressed air. 8.11 Check pressure built up time of each Unit ( 0- 7 kg/cm2) 10-12 min Cut in 6.0 kg/cm² 8.12 Check Cut in & Cut Out Setting of Main air Compressor Cut out-7.0 kg/cm² 9.0 Auxiliary Compressor 9.1 Check the carbon brush, if required to be replaced. 9.2 Check oil level. Top up if required. 9.3 Check for any leakage of oil and air. 9.4 Drain auxiliary Compressor air reservoir. 9.5 Check the foundation bolts. 9.6 Check & Record time to build up pressure 0 to 5.0 kg/cm² within 4 min Cut in 5.3 kg/cm² 9.7 Check Cut in & Cut Out Setting of Auxiliary Compressor. Cut out-6.3 kg/cm² 9.8 Check battery voltage with auxiliary compressor ON. 10.0 TCC & ACU 10.1 Clean the air intake jally of TCC / Module heat sink. 10.2 Check working of TCC blowers. 10.3 Intactness of grounding shunts. 10.4 Check the intactness of VSS cable connections. 10.5 Cleaning of TCC, ACU cabinet. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 14 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remark 11.0 L.A, C.T. & P.T. 11.1 Clean the insulators. 11.2 Check the HT Connection intactness. 11.3 Check the intactness of foundation bolts. 11.4 Check for any crack on the insulators. 12.0 Pantograph & Roof Equipment Check for any sign of external hitting / damages / cracks on Panto Pan, Rocker Assembly, Lower Frame ,Upper Frame, Base Frame, Coupling Rod, Parallel 12.1 Guide Bar (Schunk) Raising Springs, Tension bolts, Anti-balancing rod, upper articulation, Lower articulation, Eye-let Rod and Other Sub Assemblies of pantograph. In case of any abnormality replace it (SIL). Check for any OHE rubbing marks on panto pan below 12.2 Red paint line. Check thickness of Wearing Strips. It should be above > 3 mm 12.3 condemning size. Check that wearing Strips are without Sharp Edges and 12.4 ensure Screws are not projecting above the wearing strips and are properly secured. Check that there is no Gap between the Main wearing 12.5 and End wearing Strips. Ensure availability of all Bolts, Nuts, Lock-Nuts, 12.6 Spring Washers, Split pins etc. of various fittings. Check Lower Frame Assembly & Upper Frame 12.7 Assembly for excessive lateral play (transverse). Check Bow Plunger is sliding freely while pressing and 12.8 split pins are available (SIL). Check Rocker assembly for free movement (Schunk). Check the Control Box, Rubber Bellow & Rubber/PU Pipe for 12.9 any air leakage.(Schunk) Check the Servo motor, Throttle Valve, Magnet Valve for Any air leakage.(SIL) Check Horizontal Damper for Oil Leakage and smooth 12.10 operation (Schunk). Check for free movement of servo motor piston rod and 12.11 eyelet rod. (SIL) Ensure availability of all flexible shunts and check that 12.12 strands are not broken. Ensure provision of steel bracket on lower articulation to 12.13 prevent earthing of anti balancing tube after uncoupling. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 15 Sr. Description Remark Check whether rubber stopper on the base frame and MS 12.14 bracket on lower articulation is provided to prevent over turning of panto in unwired section. (SIL) 12.15 Check & record Raising and Lowering time of Pantograph. 6-10 Sec 12.16 Ensure pantograph is raising in three steps in SIL. 12.17 Clean all the Insulators with vim powder & dry cloth. 12.18 Air blow the DBR. 12.19 Visual check for any damage to grid, flashover. 12.20 Check for HT connection intactness. Check and ensure that there is no Air Leakage from the Panto 12.21 magnet valve. 10.5 kg (Shunk) 12.22 Check panto pan tension. 9.5 kg ( SIL) 13.0 VCB (Single bottle) 13.1 Check foundation bolts tightness. 13.2 Check the tightness Electrical connections. 13.3 Check for cracks and flash marks. 13.4 Clean the insulators. 13.5 Check for connection of AC earthing switch. 13.6 Clean and grease the AC earthing switch. 13.7 Check for any air leakage in VCB pneumatic connection. 14.0 DC Earthing switch 14.1 Clean & Grease the moving and fixed contact of earthing switch. 14.2 Ensure Connection tightness. 15.0 Change over switch 15.1 Check the HT Connection intactness. 15.2 Check the foundation bolts. 15.3 Clean insulator using Vim powder. 15.4 Check visually for any crack/damage. 15.5 Check tightness of all cable connections. 16.0 Control and Switch Gear Check all MCBs & Switches for normal position on the E- 16.1 Cabinet in the Motor Coach. Check for set condition of Motor Protection Switch (MPS) in 16.2 all the end panels. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 16 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remark Ensure proper locking of panel doors of E-Cabinet in D/cab & 16.3 MC, End wall panels other coaches. Ensure proper position of MVB segment address selector 16.4 switch. 17.0 AWS 17.1 Note the defects reported in defect card book. 17.2 Check and note the reading of SFBC, EBC, ISU Ensure the intactness of ISU, BAU, Indication panel, PCB card 17.3 frame, Elmex terminal, magnet valve, SPM hooter & tightness of wire connections Check the ISU handle for proper fitment & tightened if found 17.4 loose. 17.5 Ensure functioning of SPM hooter and BAU. 17.6 Check AWS MCB and ground fault. 17.7 Set wheel diameter in B4A1 card. Function test pressure test, SPM test & simulation test to be 17.8 done. 17.9 Replace speed cut off and exhaust magnet valve. 9 monthly basis Check & note the Engine magnet pulses on B1A1 card by multimeter 17.10 50 Khz-socket 1 & 3 200 +/_ 20 mv 100 Khz – soket 5 & 7 350 +/ - 25mv Check voltage on B14A1 card Socket 1-2 12v +/- 0.3 v, 0.6v 17.11 Socket 3-2 24v +/- 1.1v, 0.6v Socket 4-5 5v +/- 0.3v 17.12 Download medha/ AAL SPM data Ensure intactness of Engine magnet foundation beam, engine 17.13 magnet, JB-1, JB-II, TGs, magnet valve & cover, pipes & clamping, all fastners, washer, split spins, safety chains etc. 17.14 Check the clearance of engine magnet clearance from the rail. 17.15 Ensure TG axle attachment, dowel pins fork. Ensure the SPM is showing speed by manually rotating TG in 17.16 both directions. Ensure no brake is applied in forward direction and brake applied in reverse direction. 18.0 APC Ensure proper intactness of foundation hardware of APC 18.1 magnet. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 17 Sr. Description Remarks 18.2 Check for intactness of electrical coupler. Ensure functioning of APC receiver by passing over APC 18.3 track magnet and ensure same at SIBAS clip also. Ensure reset of APC also. 19.0 Fire Extinguisher 19.1 Check for seal is intactness. 19.2 Check for refilling date & Replace if expired. 19.3 Check for fire extinguisher mounting. 19.4 Check the condition of nozzle/ pipe & replace if punctured. 20.0 PIS/PA System & TMS 20.1 Check working of intercom. 20.2 Check working of public address from both cab. 20.3 Check working of PIS from both cabs by entering any journey. 20.4 Ensure availability of manual head code. 20.5 Check working of coach display and speakers. 21.0 Light & Fan Check operation of Lights, Fans and Ventilation switches on 21.1 50% &100% position. Check the working of all Fans and Lights in the coaches. 21.2 Attend the defects if noticed. Check working of Signal Bell / Emergency Bell & indication 21.3 LEDs. Check working of Flasher, Tail & Blinker Light and ensure 21.4 smooth operation of their Push Buttons. Check working of Head Light & Auxiliary Head Lights at both 21.5 Dim/ Bright positions. Check working of DC-DC Converter for Head light on both 21.6 normal and standby positions. 21.7 Check head light focus and adjust if required. Check working of Cab Light, Emergency Cab Light, Spot 21.8 Light & Cab Fans. Ensure smooth operation of all push button & switches in the 21.9 D/ Cab. 22.0 BATTERY Check & record Battery Voltage by operating "TEST 22.1 BATTERY VOLTAGE" push button in motor coach shunting cab after switching off battery. Check for intactness of Battery Box mounting Bracket and 22.2 Bolts. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 18 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remarks 22.3 Check the battery voltage when MC charged & record it. Check the condition of battery cover, battery box for proper 22.4 fitment. 22.5 Check the condition of battery connecting leads. 22.6 Ensure intactness of lead connections. 22.7 Check the level of electrolyte in each cell &Top up if less. 22.8 Check the voltage of each cell. 22.9 Check the specific gravity of each cell. 22.10 Apply petroleum jelly on all connections after cleaning. 22.11 Clean the battery box & trolley. 22.12 Ensure proper working of trolley & door hinges. Ensure compact placement of battery cells to avoid relative 22.13 movement during run. 23.0 Final Testing from both Driving CABs 23.1 Keep MMI in Maintenance Mode Check Healthiness of various Lamp Indication by Pushing 23.2 Test Push Button. 23.3 Check on MMI that all coaches are set. Check the Healthiness of each and every function physically which are displayed on various screens. 23.4 (Top level, Unit Level, Drive/Brake, Energy, Fault logged, V > 0 & V = 0) of MMI. 23.5 Check for any Error Message on the screen. Check ground fault in 110V DC and 110V AC circuit by 23.6 multi-meter. Record voltage between (45 - 55 V) + ve to ground and -ve to ground. 23.7 Check CB set/trip on MMI. 23.8 Check Panto Raising/Lowering timing on MMI. 6-10 Sec Check working of Fan, Light and Ventilation (both 50% and 23.9 100%). Check Changeover on MMI for 415V AC, 110V AC, 110V 23.10 DC by operating Basic Unit Isolating Switch. Check operation of Head Light, Auxiliary Head Light, 23.11 Flasher, Tail Light and Blinker Light. Check operation of Signal bell and Emergency bells and their 23.12 indication. 23.13 Check working of PA/PIS & TMS system. 23.14 Check for Healthiness of Head-code. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 19 Sr. Description Check functionality of Entering Neutral Section Push Button 23.15 by observing feed-back on SKS 12 & 13. 23.16 Check operation of "Battery Supply " switch. 23.17 Check working of Emergency OFF Loop push Button. Ensure AWS working by Pressing vigilance Push button for 8 23.18 sec. Check working of Dead man’s valve in normal and RDM 23.19 mode. Measure and record the rate of air flow of ACU & TCU ACU>5-6m/s 23.20 blowers of all four Motor coaches. TCU>7-9 m/s 23.21 Check working of audio visual and cross passing. Run down the Rake in Normal and RDM mode from both 23.22 cabs. Check AWS Speedometer and Speed Recorder and ensure no 23.23 differential error in both cabs. 23.24 Revert MMI to "Drive Mode" after completion of testing. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 20 CAMTECH/E/13-14/MM AC-DC EMU/1.0 12.6 MAINTENANCE SCHEDULE OF AC-DC (Siemens) IA (45 Days) CARRIAGE Sr. Items to be checked Remark 1.0 Driving CAB a. Check while the rake is rolling: 1. Check skidding of wheels. 2. Check unusual noise from under-gear. b. On Stationary mode: Check logbook and enter remarks regarding attention against 1. any adverse remarks given logbook. 2. Check the function on MMI for all coaches. 3. Check brake continuity test. 4. Check Signal bell – I continuity. 5. Check Signal bell – II continuity 6. Check working of intercom and PA system. 7. Check working of AWS. Check proper working of Duplex, BC, Guard's and Parking Brake 1.1 gauges. 1.2 Check and ensure for Wooden Wedges provided in each driver cab. 4 nos. Check and ensure for Fire Extinguishers provided in each driver 2 nos. 1.3 cab. Ensure expiry date. 1.4 Ensure cleaning of look out glasses (M/Man side & Guard side). 1.5 Ensure cleaning of D/cab & Driver Desk. Check for smooth operation of guard emergency handle and proper 1.6 ON/OFF stenciling. Check for any air leakage from pipe & couplings of Guard 1.7 emergency handle. 2.0 ACP 2.1 Check working of ACP by pulling handle from each coach (east & west side) and ensure flag is coming out sufficiently and getting re- set. 2.2 Ensure that coach in which ACP operated is correctly displayed on the MMI. 3.0 Air Spring Suspension 3.1 Check the foundation allen bolts intactness. 3.2 Check air spring for any crack, dent marks, leakage and hitting marks on air spring. 3.3 Check the foundation and fitment of vertical dampers & Replace if not working. 3.4 Check the Leveling Valve assembly for any leakage & Replace if required. 3.5 Check the Installation lever and adjust the clearances if found abnormal. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 21 Sr. Items to be checked Remark 3.6 Check the working of all cocks provided for air spring & Replace if required. 3.7 Ensure that Leveling Valve installation Rod is in vertical position. 3.8 Ensure proper position of all air springs cocks. 3.9 Drain Air Spring Reservoir and ensure availability of baffle plates to protect drain cock. 3.10 Check all the Pipes & Couplings for any air leakage and attend it. 3.11 Check for any rubbing / air leakage/ damage to the air spring flexible hoses and replace if required. 3.12 Ensure availability & intactness of bolster liner locking plate. 3.13 Check the welded joints of Air spring base frame for any cracks/ breakages. 3.14 Check the intactness of foundation bolts of 20 liters tank and healthiness of release valve. 3.15 Check the function of duplex check valve as per work instruction. 3.16 Ensure the foundation bolt intactness of leveling valve protection plate. 4.0 Air Drier 4.1 Check for intactness of mounting hardware. 4.2 Check for any air leakage from Duplex piston valve. Purging of air dryer with interval of 120 secs for Knorr 4.3 Bremse make and 60 sec. for SIL make. 4.4 Check for alternate operation of regenerative towers. Check the healthiness of desiccant by observing colour of Blue = OK, 4.5 Yellow = warning humidity indicator. Check and observe the water content in MR by dew point 4.6 meter. Visual inspection for external damages to air dryer and its 4.7 pipe lines. 4.8 Check the tightness of Electrical supply connector. 5.0 Parking Brake Check for proper fitment of Parking Brake Cylinder 5.1 foundation, Brake Arm, Cup Sleeve, Release handle wire rope etc. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 22 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark 5.2 Check the Parking Brake Cylinders operation, (wheel No. 1- 3, 5-7 in DTC and middle NDTC) and ensure physically application and release of the brakes. 5.3 Check the working of Double Check Magnet valve. Replace if found leakage / not working. 5.4 Ensure the intactness of Double Check Magnet valve foundation allen bolts. 5.5 Ensure releasing of brakes with rope handle. 6.0 Buffers & Schaku Coupler 6.1 Ensure the intactness of Cup-Sleeve Bolt. 6.2 Check the condition of Articulation Bearing Bolts and Bush. Check for any air leakage from MR & BP Pipe bracket and 6.3 bushing/ elbow clamps. 6.4 Check the condition of centering device & leaf spring. 6.5 Check the tightness of check nut and wing nut. 7.0 Piping & Reservoirs Check for any air leakage/rubbing & ensure availability of 7.1 clamps. Check welding joints, split pins, fixing bolts of all the 7.2 reservoirs. Check for any isolation of EP/ AUTO/ Bogie & coupling 7.3 cocks and attend if isolated. 7.4 Ensure smooth operation of EP, Auto & Bogie cocks. Check for any Damage to Piping and Cocks & Replace 7.5 defective/ leaking cocks. Check intactness of foundation Bolts of MR, Auxiliary and 7.6 Air Spring Reservoirs & Ensure availability of split pins. 7.7 Check the intactness of Reservoirs of MS straps. 7.8 Drain all the Reservoirs with drain cocks. 7.9 Check the operation of MR, BP , Bogie isolating and drain cocks & Replace if any leakage. 7.10 Check for leakages flexible hoses. 7.11 Check condition of leading coach hose pipes. 7.12 Observe any sign of air leakage and looseness of end fittings. 7.13 Check rubbing of hose pipes and shifting of end nipples. 7.14 Check MR/BP cocks leakage by closing cocks. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 23 Sr. Items to be checked Remark 8.0 Bogie 8.1 Check Bogie frame, Bolster and coach under frame for any crack / damages or excessive wear. 8.2 Check coach sole bar and under frame for any crack / hitting marks. 8.3 Check condition of liner between Bogie & Bolster. 8.4 Check for healthiness and foundation intactness of lateral and vertical friction dampers. Check for signs of oil leakages. 8.5 Check Palm-pull rods for any crack/ bend. 8.6 Check condition of bushes, pins and safety Chains. 8.7 Check availability of pins with Bulb Cotters & Split Pins. 8.8 Check Side Bearer for Crack or Oil Leakage. 8.9 Check for Side Bearer cover jam/ loose. 8.10 Check for intactness of Center Pivot or any crack. 8.11 Check Axle Springs for any Breakage/ Permanent set. 8.12 Check and ensure the intactness of Cattle guard, Buffer foundation Bolts. Check for hitting/rubbing between bolster and bogie in lateral < 3mm 8.13 direction. Check for condition of liner plate and proper clearance. 8.14 Check brake shoe hanger assembly for any excessive play, crack & damages. 8.15 Check intactness of rubber snubbers and crown packing on axle box. 8.16 Check for any damage or abnormality on brake yoke assembly. 8.17 Check the condition of safety brackets and intactness of fixing bolt. 8.18 Check height of cattle guard from rail level. 150 to 200 mm 9.0 Brake Cylinder 9.1 Check fixing Bolts of Brake Cylinders for any damage or slackness. 9.2 Check Brake Rigging parts i.e. pins, Nut Bolts, Cutters, Split Pins, Brake Block key, Brake shoe head pins for missing, worn out, slackness. 9.3 Check Brake Hanger Safety Brackets and Safety Stopper Plates are intact. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 24 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark 9.4 Replace worn out Brake Blocks. 9.5 Check Brake Cylinder Piston not infringing with U Bracket in brake applied condition. 10.0 Brake Block 10.1 Adjust gap between brake blocks and wheel in released 12 mm to 15 condition. mm 10.2 Ensure tightness of brake shoe key. 11.0 Brake Rigging 11.1 Check Nuts, Bolts, Pins, Cotters, Bush, and Washers for intactness and wear, replace if required. 11.2 Ensure availability of Stopper Plates. 11.3 Check Brake Hangers, Brake Beams and other Brake Rigging components for intactness and wear. 11.4 Lubricate all the moving parts by applying oil/ grease. 12.0 Dashpot 12.1 Check the oil level, top up if required. Record the quantity of M/C 97 mm oil topped up in Dash pot. 12.2 Check for any breakage of dashpot spring and dashpot protective tube. 12.3 Check D/Pot bottom rubber packing for torn & damage. 12.4 Check intactness of dashpot safety loop brackets. 12.5 Ensure intactness of oil filling nipples / cap. 13.0 Wheel &Axle Box 13.1 Check for tilting of Axle Box. 13.2 Check Wheel with tapping hammer for any dull sound, On tyred wheels intactness of keys and glut ring, crack, flow of metal at surface. 13.3 Check Axle Box cover for any cracks and grease leakage. 13.4 Check Axle Box Covers for intactness of bolts and availability of Split Pins. 13.5 Check the Wheel for Flat, Chipping and other defects. 13.6 Take Wheel profile and check for wheel defect such as shell tread, Grooved / Flat tyre, Sharp flanges, Deep Flanges, Thin Flanges, Root Wear & other defects. 13.7 Visually check for any abnormality like disc shifting Axles, MSUs etc. 13.8 Check the temperature of Axle boxes with the help of While rake temperature gun. placed in shed Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 25 Sr. Items to be checked Remark 14.0 Furnishing Items 14.1 Ensure healthiness of both side curtains and V-Cool films in both D-Cabs. 14.2 Check M/man seat for smooth up/down and Forward/Reverse movement operation. 14.3 Check Grab Handles and Center Pole for proper intactness and welding & Provide missing grab handles. 14.4 Check operation (open/ close/ locking) of D/cab doors and windows. 14.5 Check operation (open/close/locking) of doors in passenger area / check for any damages. 14.6 Check the seats for any damage and foundation bolt intactness. Attend broken Seats & Seat Frames and torn first class seats. 14.7 Ensure availability of safety covers of Articulation Bearing bolt. 14.8 Check in Handicap compartment for passenger amenities. 14.9 Clean the drain holes on the flooring in passenger area. 14.10 Check the interior & exterior stenciling of coach. 14.11 Ensure intactness of Door way side partition foundations. 14.12 Ensure intactness Coach body end panel partition. 14.13 Ensure intactness Partition SS sheet welding and molding screw. 14.14 Ensure intactness of the hatch door bracket welding from inside. 14.15 Ensure intactness of hatch door nut and bolt from inside. 14.16 Ensure intactness of hatch door screw from outside. 14.17 Ensure intactness of hatch door fixing chain and clamp inside the HT compartment. 15.0 Testing Put MMI in maintenance mode & Switch on DCS and 15.1 observe on MMI. i) Application of holding brakes in all coaches. ii) DCS key “ON” position. 0.8 Kg/cm2 iii) DCS key “OFF” position 1.2 Kg/cm2 15.2 EP Brake Application i) Application Timing 4-6 sec ii) Release Timing 4-6 sec 15.3 Auto Brake Application i) Application Timing 6-10 Sec ii) Release Timing 10-15 sec Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 26 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Items to be checked Remark 15.4 Emergency brake with Power Brake Controller i) Application Timing 6-10 Sec ii) Release Timing 10-15 sec 15.5 Emergency brake with Pneumatic Brake Controller i) Application Timing 6-10 Sec ii) Release Timing 10-15 sec iii) Check EP application and releasing time. iv) Check Auto application and releasing time. 15.6 Check working of Brake Controller at all positions & Ensure No leakage from Brake Controller in release/ auto lap position. 15.7 Ensure No air leakage from EP unit in both released and applied condition. 15.8 Ensure no EP Unit should be Hunting. 15.9 Ensure the provision of safety valve in all brake units. 15.10 Ensure the functioning of Brake Unit Safety Valve by applying Auto Brake. 15.11 Ensure functioning of Emergency Valve in normal and RDM. 15.12 Ensure functioning of Guards Emergency Brake. 15.13 Check all Brake Cylinders for Leakage. 16.0 Pneumatic Testing Check BP pressure charging time from both cabs 0 to 4.7 2.5 to 3 minutes 16.1 kg/cm2. for 12 car rake 16.2 Measure brake pipe pressure on Duplex gauge: i) Pre-Testing Final Testing ICS ON Cab-1 BP Cab-1_______ BP Cab-1_______ BP Cab-2 _______ BP Cab-2_______ * Pressure difference in both Cab's RDK should be > 0.1kg/cm2 Pre-Testing Final Testing ICS ON Cab-2 ii) BP Cab-1_______ BP Cab-1_______ BP Cab-2 _______ BP Cab-2_______ 16.3 Check 1 kg/cm2 MR pressure dropping time. 16.4 Check 1 kg/cm2 BP pressure dropping time. 16.6 Ensure MR and BP pipe pressure continuity. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 27 Sr. Items to be checked Remark Ensure proper working of Duplex Pressure Gauge, BC 16.7 Gauge, Parking Brake and Guard's Gauge. 16.8 Ensure physically application & release of Parking Brake. Ensure Parking Brake gauge shows 0.0 kg/cm2 pressure in 16.9 applied condition and 5 kg/cm2 in released condition. 16.10 Ensure the working of Parking Brake Push button. 16.11 Ensure smooth operation of Horn Foot Valve. 16.12 Ensure quality sound of horns. 16.13 Ensure correct position of check nut in Escort make ICS. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 28 CAMTECH/E/13-14/MM AC-DC EMU/1.0 12.7 MAINTENANCE SCHEDULE OF AC-DC (Siemens) IC (180Days) ELECTRICAL Sr. Description Remark 1.0 Pre-Testing 1.1 Keep MMI in Maintenance Mode. 1.2 Check on MMI that all coaches are set. Check the Healthiness of each and every function physically which are displayed on various screens (Top level, Unit 1.3 Level, Drive/Brake, Energy, Fault logged, V > 0 & V = 0) of MMI. 1.4 Check for any Error Message on the screen. Check ground fault in 110V DC circuit by multimeter. 1.5 Record voltage between ( 45 - 55 V) '+ ve to ground, -ve to ground. Check ground fault in 110V AC circuit by multimeter. 1.6 Record voltage between ( 45 - 55 V). 1.7 Check and ensure all MCB are set on E-Cabinet. Check and ensure all rotary switches are set in their relevant 1.8 normal position E-Cabinet 1.9 Check CB set/trip on MMI. Check Changeover on MMI for 415V AC, 110V AC, 110V 1.10 DC by operating Basic Unit Isolating Switch. Check functionality of Entering Neutral Section and cruise 1.11 control Push Button by observing feedback on SKS 12 & 13. 1.12 Check operation of "BA Reset" switch. 1.13 Check working of Emergency OFF Loop push Button. Observe BECU Speed Sensors Feed Back Signals in 1.14 "Observer" by laptop. Check working of Dead man valve in normal and RDM 1.15 mode. 1.16 Ensure the functions of E-Cabinet switches. Check the Healthiness of MVB Line with MVB bus tester as 1.17 per existing TC. Measure the rate of air flow of ACU of all four Motor > 5-6 m/s 1.18 coaches after fitter cleaning. Measure the rate of air flow of TCU blowers of all four > 8-9 m/s 1.19 Motor coaches after air blowing. 1.20 Check working of audio visual. Down load the events of all Four TCU & both CCU and 1.21 analyze for any fault message. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 29 Sr. Description Remark 1.22 Take energy consumed readings and reset the both counters. Take energy re-generated readings and reset the both 1.23 counters. 1.24 Take distance (km) readings and reset the both counters. Note the brake cylinder pressures in each coach with SIBAS 1.25 monitor both normal and redundant modes of BCU. 2.0 Master Controller Check the operation of Dead-man, Forward/ Reverse, DCS 2.1 Key, Traction, brake and coast position. 2.2 Visually check Encoder cable for any insulation damage. Check all electrical & micro switches connections for 2.3 intactness. 2.4 Visually check the operation of all micro switches. 2.5 Ensure no excessive play in T-handle 3.0 Push buttons & Switches Check & ensure smooth operation with their indications of 3.1 all push buttons on Driver desk Check Healthiness of various Lamp Indication by Pushing 3.2 Test Push Button. 3.3 Check the operation of all the switches. 4.0 End wall Check intactness of wiring connection at MCB, Relays, 4.1 Contactors & etc. of all coaches. Check the LV connections for tightness in train-line junction 4.2 box. 4.3 Clean the end wall panels. 5.0 Transformer Check colour of silica gel. It should BLUE/ ORANGE. Heat 5.1 the silica gel if found grey. 5.2 Check for any oil leakage. 5.3 Check working of radiator blower fans & oil pump. 5.4 Check for any hitting mark or damage. 5.5 Transformer cleaning to be done. Oil level to be checked. It should be in between the low level 5.6 and 300 mark. 5.7 Ensure Earthing connection intactness. 5.8 Check the foundation bolts intactness. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 30 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remark 5.9 Ensure Radiator fins cleanliness. Check the BDV & DGA of Transformer oil & filter if BDV 5.10 low. 6.0 Traction Motor 6.1 Record the temperature at DE side of bearing. While rake placed in shed 6.2 Record the temperature at NDE side of bearing. 6.3 Visual inspection for any external hitting or damages. Check intactness of TM mounting bolts & MSU half shell 6.4 bolts. 6.5 Check tightness of gear case bolts. 6.6 Check the oil level and colour of gear case oil. 6.7 Check intactness of body earthing. Check for rubbing and damage of Traction Motor cables and 6.8 their proper securing. 6.9 Visual inspection for damage to sandwich packing. 6.10 Clean suction air filters by dry compressed air. 6.11 Check for proper fitment and tightness of bellow. 6.12 Check the size of ERB and replace if under size. Check the healthiness spring tension of ERB and replace if 6.13 defective. 6.14 Check and ensure intactness of gaskets & fiber bush of ERB. 6.15 NDE bearing greasing. During IInd IC 6.16 Check for any damage. Replace if required. 6.17 Cleaning of Traction motor filter. 7.0 Suspension Tube Assembly 7.1 Check for any sign of over-heating of bearings. 7.2 Check that the housing bolts are intact. 7.3 Check for any abnormality. 7.4 Both end MSU bearing greasing to be done. During IInd IC 8.0 Main Compressor 8.1 Clean externally compressor body & radiator. Check operation of compressor by way of observing running 8.2 sound, feel temperature by hand. Check for any oil or air leakage from joints, suction or 8.3 delivery pipes. 8.4 Check condition of resilient mounting for intactness. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 31 Sr. Description Remarks 8.5 Check & ensure tightness of foundation bolts. 8.6 Check vacuum indicator on silencer (suction filter) i) Colourless–ok ii) Red Colour – Suction filter defective 8.7 Ensure proper tightness of delivery pipe. 8.8 Ensure the healthiness of mounting wire ropes. 8.9 Clean air suction filters by dry compressed air. 8.10 Check pressure built up time of each Unit (0- 7 kg/cm2). 10-12 min Check Cut in & Cut Out Setting of Main air Cut in- 6.0 kg/cm² 8.11 Compressor. Cut out -7.0 kg/cm² 8.12 Check oil level. 100% replacement in IInd IC. 9.0 Auxiliary Compressor 9.1 Check the carbon brush, if required to be replaced. 9.2 Check oil level, Top up if required. 9.3 Check for any leakage of oil and air. 9.4 Drain auxiliary Compressor air reservoir. 9.5 Check the foundation bolts. Check & Record time to build up pressure up to 6.5 9.6 kg/cm². Cut in- 5.3 kg/cm² 9.7 Check Cut in & Cut Out Setting of Auxiliary Compressor Cut out- 6.3 kg/cm² 9.8 Ensure oil level and top up if required. 10.0 TCC & ACU & CCU 10.1 Clean the air intake jally of TCC / Module heat sink. 10.2 Check working of TCC blowers. 10.3 Check intactness of grounding shunts. 10.4 Check the intactness of VSS cable connections. 10.5 Cleaning of CCU. 10.6 Cleaning of TCC, ACU cabinet. Check the contactors K1, K4, K5, K6, and clean the arc 10.7 chutes if required, and check interlocks. 11.0 L.A., C.T. & P.T. 11.1 Clean the insulators. 11.2 Check the HT Connection intactness. 11.3 Check the intactness of foundation bolts. 11.4 Check for any crack on the insulators. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 32 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remarks 12.0 Pantograph & Roof Equipment 12.1 Check for any sign of external hitting / damages / cracks on Panto Pan, Rocker Assembly, Lower Frame ,Upper Frame, Base Frame, Coupling Rod, Parallel Guide Bar (Schunk), Raising Springs, Tension bolts, Anti-balancing rod, upper articulation, Lower articulation, Eye-let Rod and Other Sub Assemblies of pantograph (SIL). In case of any abnormality replace it. Check for any OHE rubbing marks on panto pan below Red 12.2 paint line. Check thickness of Wearing Strips. It should be above >3 mm 12.3 condemning size. Check that wearing Strips are without Sharp Edges and 12.4 ensure Screws are not projecting above the wearing strips and are properly secured. Check that there is no Gap between the Main wearing and 12.5 End wearing Strips. Ensure availability of all Bolts, Nuts, Lock-Nuts, Spring 12.6 Washers, Split pins etc. of various fittings. Check Lower Frame Assembly & Upper Frame Assembly 12.7 for excessive lateral play (transverse). Check Bow Plunger is sliding freely while pressing and split 12.8 pins are available(SIL). Check Rocker assembly for free movement (Schunk). Check the Control Box, Rubber Bellow & Rubber/PU Pipe for any air leakage. (Schunk). 12.9 Check the Servo motor, Throttle Valve, Magnet Valve for Any air leakage. (SIL) Check Horizontal Damper for Oil Leakage and smooth 12.10 operation (Schunk). Check for free movement of servo motor piston rod and 12.11 eyelet rod. (SIL) Ensure availability of all flexible shunts and check that 12.12 strands are not broken. Ensure provision of steel bracket on lower articulation to 12.13 prevent earthing of anti balancing tube after uncoupling. Check whether rubber stopper on the base frame and MS 12.14 bracket on lower articulation is provided to prevent over turning of panto in unwired section (SIL). 12.15 Check & record Raising and Lowering time of Pantograph 6-10 Sec. 12.16 Ensure pantograph is raising in three steps (SIL). 12.17 Clean all the Insulators with vim powder & dry cloth. 12.18 Clean and Air blow the DBR. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 33 Sr. Description Remark 12.19 Visual check for any damage to grid, flashover. 12.20 Check for HT connection intactness. Check and ensure that there is no Air Leakage from the 12.21 Panto magnet valve. 10.5kg Shunk) 12.22 Check panto tension. / 9.5 kg ( SIL) 13.0 VCB 13.1 Check foundation bolts tightness. 13.2 Check the tightness Electrical connections. 13.3 Check for cracks and flash marks. 13.4 Clean the insulators. 13.5 Check for connection of AC earthing switch. 13.6 Clean and grease the AC earthing switch. 13.7 Check for any air leakage in VCB pneumatic connection. 13.8 Draining of pressure regulator and air reservoir. 14.0 DC Earthing switch 14.1 Clean & Grease the moving and fixed contact. 14.2 Ensure Connection tightness. 15.0 Change over switch 15.1 Check the HT Connection intactness. 15.2 Check the foundation bolts. 15.3 Clean insulator using Vim powder. 15.4 Check visually for any crack/ damages. 15.5 Check tightness of all cable connections. 16.0 Control and Switch Gear Check all MCBs & Switches for normal position on the E- 16.1 Cabinet in the Motor Coach. Check for set condition of Motor Protection Switch (MPS) 16.2 in all the end panels. Testing & Calibration of compressor & Control pressure 16.3 governors. Check for any damages to ceramic parts and grid of 16.4 grounding resistor. 16.5 Check the foundation for intactness. Check the intactness of grounding shunts and provide if 16.6 missing. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 34 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remark 16.7 Clean and air blow the grounding resistor. Ensure proper locking of panel doors of E-Cabinet in 16.8 D/cab & MC, End wall panels other coaches. Ensure proper position of MVB segment address selector 16.9 switch. 17.0 AWS 17.1 Note the defects reported in defect card book. 17.2 Check and note the reading of SFBC, EBC, ISU. Ensure the intactness of ISU, BAU, Indication panel, PCB 17.3 card frame, Elmex terminal, magnet valve, SPM hooter & tightness of wire connections. Check the ISU handle for proper fitment & tightened if 17.4 found loose. 17.5 Ensure functioning of SPM hooter and BAU. 17.6 Check AWS MCB and ground fault. 17.7 Set wheel diameter in B4A1 card. Function test pressure test, SPM test & simulation test to 17.8 be done. 17.9 Replace speed cut off and exhaust magnet valve. 9 monthly Check & note the Engine magnet pulses on B1A1 card by multimeter 17.10 50 Khz-socket 1 & 3 = 200 +/- 20 mv 100 Khz – socket 5 & 7 = 350 +/ - 25mv Check voltage on B14A1 card Socket 1-2 = 12v +/- 0.3v, 0.6v 17.11 Socket 3-2 = 24v +/- 1.1v, 0.6v Socket 4-5 = 5v +/- 0.3v 17.12 Download Medha/ AAL SPM data Ensure intactness of Engine magnet foundation beam, engine magnet, JB-1, JB-II, TGs, magnet valve & cover, 17.13 pipes & clamping, all fasteners, washer, split spins, safety chains etc. Check the clearance of engine magnet clearance from the 17.14 rail. 17.15 Ensure TG axle attachment, dowel pins fork. Ensure the SPM is showing speed by manually rotating 17.16 TG in both directions. Ensure no brake is applied in forward direction and brake applied in reverse direction. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 35 Sr. Description Remark 18.0 APC Ensure proper intactness of foundation hardware of APC 18.1 magnet and clearance of APC receiver from rail level. 18.2 Check for intactness of electrical coupler. Ensure functioning of ACP receiver by passing over APC 18.3 track magnet and ensure same at SIBAS clip also. Ensure reset of ACP also. 19.0 Fire Extinguisher 19.1 Check for seal intactness. 19.2 Check for refilling date & Replace if expired. 19.3 Check for fire extinguisher mounting. 19.4 Check the condition of nozzle/ pipe & replace if punctured. 20.0 PIS/PA System & TMS 20.1 Check working of intercom. 20.2 Check working of public address from both cabs. Check working of PIS from both cabs by entering any 20.3 journey. 20.4 Ensure availability of manual head code. 20.5 Check working of coach display and speakers. 21.0 Light & Fan Check operation of Lights, Fans and Ventilation switches 21.1 on 50% &100% position. Check the working of all Fans and Lights in the coaches. 21.2 Attend the defects if noticed. Check working of Signal Bell / Emergency Bell & 21.3 indication LEDs. Check working of Flasher, Tail & Blinker Light and 21.4 ensure smooth operation of their Push Buttons. Check working of Head Light & Auxiliary Head Lights at 21.5 both Dim/ Bright positions. Check working of DC-DC Converter for Head light on 21.6 both normal and standby positions. 21.7 Check head light focus and adjust if required. Check working of Cab Light, Emergency Cab Light, Spot 21.8 Light & Cab Fans. Ensure smooth operation of all push button & switches in 21.9 the D/ Cab. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 36 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Description Remark 22.0 BATTERY Check & record Battery Voltage by operating "TEST 22.1 BATTERY VOLTAGE" push button in motor coach shunting cab after switching off battery. Check for intactness of Battery Box mounting Bracket and 22.2 Bolts. 22.3 Check the battery voltage when MC charged & record it. Check the condition of battery cover, battery box for 22.4 proper fitment. 22.5 Check the condition of battery connecting leads. 22.6 Ensure intactness of lead connections. 22.7 Check the level of electrolyte in each cell &Top up if less. 22.8 Check the voltage of each cell. 22.9 Check the specific gravity of each cell. 22.10 Apply petroleum jelly on all connections after cleaning. 22.11 Clean the battery box & trolley. 22.12 Ensure proper working of trolley & door hinges. Ensure compact placement of battery cells to avoid 22.13 relative movement during run. 22.14 Clean and blowing of battery fuse box. 23.0 Final Testing from both Driving CABs 23.1 Keep MMI in Maintenance Mode Check Healthiness of various Lamp Indication by 23.2 Pushing Test Push Button. 23.3 Check on MMI that all coaches are set. Check the Healthiness of each and every function physically which are displayed on various screens. 23.4 (Top level, Unit Level, Drive/ Brake, Energy, Fault logged, V > 0 & V = 0) of MMI. 23.5 Check for any Error Message on the screen. Check ground fault in 110V DC and 110V AC circuit by 23.6 multimeter. Record voltage between (45 - 55 V), + ve to ground, -ve to ground. 23.7 Check CB set/ trip on MMI. 23.8 Check Panto Raising/Lowering timing on MMI. 6-10 Sec Check working of Fan, Light and Ventilation (both 50% 23.9 and 100%). Check Changeover on MMI for 415V AC, 110V AC, 23.10 110V DC by operating Basic Unit Isolating Switch. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 37 Sr. Description Remark Check operation of Head Light, Auxiliary Head Light , 23.11 Flasher, Tail Light and Blinker Light. Check operation of Signal bell and Emergency bells and 23.12 their indication. 23.13 Check working of PA/ PIS. 23.14 Check for Healthiness of Head-code. Check functionality of Entering Neutral Section Push 23.15 Button by observing feed-back on SKS 12 & 13. 23.16 Check operation of "Battery Supply" switch. 23.17 Check working of Emergency OFF Loop push Button. Ensure AWS working by Pressing vigilance Push button 23.18 for 8 sec. Check working of Dead man valve in normal and RDM 23.19 mode. Measure and record the rate of air flow of ACU & TCU ACU >5-6 23.20 blowers of all four Motor coaches. m/s TCU >7- 9 m/s 23.21 Check working of audio visual and cross passing. Run down the Rake in Normal and RDM mode from both 23.22 cabs. Check AWS Speedometer and Speed Recorder and ensure 23.23 no differential error in both cabs. 23.24 Revert MMI to "Drive Mode" after completion of testing. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 38 CAMTECH/E/13-14/MM AC-DC EMU/1.0 12.8 MAINTENANCE SCHEDULE OF AC-DC (Siemens) IC (180Days) CARRIAGE S.N. Items to be checked Remark 1.0 Driving-CAB Check proper working of Duplex, BC, Guard's and 1.1 Parking Brake gauges. 1.2 Check for availability of Wooden Wedges. 04 nos. 1.3 Check for availability of Fire Extinguishers. 02 nos. Ensure cleaning of look out glasses (M/Man side & Guard 1.4 side). 1.5 Ensure cleaning of D/cab & Driver Desk Check for smooth operation of guard emergency handle 1.6 and proper ON/OFF stenciling Check for any air leakage from pipe & couplings of Guard 1.7 emergency handle. a. Check while the rake is rolling: 1. Check skidding of wheels. 2. Check unusual noise from under-gear. b. On Stationary mode: Check logbook and enter remarks regarding attention 1. against any adverse remarks given logbook. 2. Check the function on MMI for all coaches. 3. Check brake continuity test. 4. Check Signal bell – I continuity. 5. Check Signal bell – II continuity 6. Check working of intercom and PA system. 7. Check working of AWS. 2.0 ACP 2.1 Check working of ACP by pulling handle from each coach (east & west side) and ensure flag is coming out sufficiently and getting reset. 2.2 Ensure that coach in which ACP operated is correctly displayed on the MMI. 2.3 Overhauling and lubrication of ACP mechanism. 3.0 Air Spring Suspension 3.1 Check the foundation allen bolts intactness. 3.2 Check air spring for any cracks, dent marks. leakages and hitting marks on air spring. Chapter 12 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 39 Sr. Remark Items to be checked No. 3.3 Check the foundation and fitment of vertical dampers & Replace if not working. 3.4 Check the Leveling Valve assembly for any leakage & Replace if required. 3.5 Check the Installation lever and adjust the clearances if found abnormal. 3.6 Check the working of all cocks provided for air spring & Replace if required. 3.7 Ensure that Leveling Valve installation Rod is in vertical position. 3.8 Ensure proper position of all air springs cocks. 3.9 Drain Air Spring Reservoir and ensure availability of baffle plates to protect drain cock. 3.10 Check all the Pipes & Couplings for any air leakages and attend it. 3.11 Check for any rubbing / air leakage/ damage to the air spring flexible hoses and replace if required. 3.12 Ensure availability & intactness of bolster liner locking plate. 3.13 Check the welded joints of Air spring base frame for any crack/ breakages. 3.14 Check the intactness of foundation bolts of 20 ltrs. tank and healthiness of release valve. 3.15 Check the function of duplex check valve as per work instructions. 3.16 Ensure the foundation bolt intactness of leveling valve protection plate. 4.0 Air Drier 4.1 Check for intactness of mounting hardware. 4.2 Check for any air leakage from Duplex piston valve. 4.3 Purging of air dryer with interval of 120 secs. 4.4 Check for alternate operation of regenerative towers. Check the healthiness of desiccant by observing colour of Blue = OK, 4.5 Yellow = humidity indicator. warning Check and observe the water content in MR by dew point 4.6 meter. Visual inspection for external damages to air dryer and its 4.7 pipe lines. 4.8 Check the tightness of Electrical supply connector. Maintenance Manual for AC-DC EMU (Siemens) Chapter 12 40 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Remark Items to be checked No. 5.0 Parking Brake Check for proper fitment of Parking Brake Cylinder 5.1 foundation, Brake Arm, Cup Sleeve, Release handle wire rope etc. 5.2 Check the Parking Brake Cylinders operation, (wheel No. 1-3, 5-7 in DTC and middle NDTC) and ensure physically application and release of the brakes. 5.3 Check the working of Double Check Magnet valve. Replace If found leakage / not working. 5.4 Ensure the intactne